User Guide MHM-97453, Rev 1 April 2014 CSI 2600 Machinery...

User GuideMHM-97453, Rev 1

April 2014

CSI 2600 Machinery Health™ Expert

User Guide

Copyright

© 2014 by Emerson Process Management. All rights reserved.

No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into anylanguage in any form by any means without the written permission of Emerson.

Disclaimer

This manual is provided for informational purposes. EMERSON PROCESS MANAGEMENT MAKES NO WARRANTY OF ANY KIND WITHREGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE. Emerson Process Management shall not be liable for errors, omissions, or inconsistencies that may becontained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.Information in this document is subject to change without notice and does not represent a commitment on the part of EmersonProcess Management. The information in this manual is not all-inclusive and cannot cover all unique situations.

Trademarks and Servicemarks

See http://www2.emersonprocess.com/siteadmincenter/PM%20Central%20Web%20Documents/marks.pdf

All other marks are property of their respective owners.

Patents

The product(s) described in this manual are covered under existing and pending patents.

CE Notice

Emerson Process Management products bearing the symbol on the product or in the user’s manual are in compliance withapplicable EMC and Safety Directives of the European Union. In accordance with CENELEC standard EN 50082-2, normal intendedoperation is specified as follows: 1. The product must not pose a safety hazard. 2. The product must not sustain damage as a resultof use under environmental conditions specified in the user documentation. 3. The product must stay in or default to an operatingmode that is restorable by the user. 4. The product must not lose program memory, user-configured memory (e.g., routes), orpreviously stored data memory. When apparent, the user may need to initiate a reset and/or restart of a data acquisition inprogress. A Declaration of Conformity certificate for the product is on file at the appropriate Emerson Process Management officewithin the European Community.

Contents

Chapter 1 CSI 2600 Machinery Health Expert ..................................................................................11.1 CSI 2600 overview ....................................................................................................................... 11.2 User Guide overview .................................................................................................................... 11.3 User Guide conventions .............................................................................................................. 21.4 Technical support ........................................................................................................................ 2

Chapter 2 Introduction to the CSI 2600 ...........................................................................................32.1 CSI 2600 out of the box ............................................................................................................... 32.2 Optional services ......................................................................................................................... 62.3 CSI 2600 monitoring requirements ..............................................................................................62.4 Precautions ................................................................................................................................. 62.5 Safety notes .................................................................................................................................7

Chapter 3 Getting started .............................................................................................................. 93.1 Remove the CSI 2600 from the case ............................................................................................ 93.2 Turn on the CSI 2600 ................................................................................................................. 103.3 Turn off the CSI 2600 ................................................................................................................. 113.4 CSI 2600 fuse access ..................................................................................................................113.5 Data collection overview ........................................................................................................... 123.6 Data recorder modes .................................................................................................................123.7 Store data on a NAS hard drive ...................................................................................................133.8 Network configuration .............................................................................................................. 143.9 System architecture .................................................................................................................. 153.10 Access the termination board .................................................................................................... 183.11 Connectivity .............................................................................................................................. 19

Chapter 4 Hardware configuration: overview .............................................................................. 234.1 Gross Scan monitoring .............................................................................................................. 234.2 Spectral Scan ............................................................................................................................. 244.3 Transient data capture ...............................................................................................................244.4 Install a module ......................................................................................................................... 244.5 Remove a module ......................................................................................................................244.6 6560 Processor module ............................................................................................................. 254.7 CSI 2600 signal inputs ................................................................................................................284.8 6510 Signal Input module ..........................................................................................................294.9 Mounting accelerometers ......................................................................................................... 334.10 Mounting tachometers ..............................................................................................................414.11 Eddy current sensors ................................................................................................................. 44

Chapter 5 Software configuration ................................................................................................ 455.1 System overview diagram ..........................................................................................................455.2 Connect the CSI 2600 to the network server ..............................................................................465.3 Configuration overview ............................................................................................................. 465.4 Install AMS Machinery Manager ................................................................................................. 475.5 Configure the computer's IP address ......................................................................................... 475.6 Configure the FTP server to download firmware ........................................................................ 485.7 Configure boot parameters with a terminal emulator ................................................................ 515.8 Add an Online Server to RBM Network Administration ...............................................................58

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Chapter 6 Data collection and analysis ......................................................................................... 616.1 View or edit IP addresses with the unit .......................................................................................616.2 Verify or assign IP addresses to the database ............................................................................. 626.3 Database configuration: overview ............................................................................................. 626.4 Online Watch overview ..............................................................................................................666.5 Archive management ................................................................................................................ 696.6 Create archives manually ...........................................................................................................706.7 Disable archive predicates ......................................................................................................... 706.8 Stop transient acquisition .......................................................................................................... 716.9 Remove an archive from the Transient Archive Status tab ..........................................................716.10 Change databases when moving the unit to a new machine ...................................................... 72

Appendices and referenceAppendix A Specifications ...............................................................................................................73

A.1 CSI 2600 product specifications .................................................................................................73A.2 Module specifications ................................................................................................................74

Appendix B System calibration ....................................................................................................... 83B.1 The CSI 6560 Processor module .................................................................................................83

Appendix C Data types ................................................................................................................... 87C.1 Gross Scan analysis .................................................................................................................... 87C.2 Spectral analysis ........................................................................................................................ 88C.3 Time Waveform analysis ............................................................................................................89C.4 Non-Vibration unit analysis types .............................................................................................. 90C.5 Set DC offset ..............................................................................................................................90

Appendix D Internal wiring of the CSI 2600 ..................................................................................... 93D.1 Rear termination panel .............................................................................................................. 93D.2 Internal wiring diagram for the CSI 2600 ....................................................................................96D.3 Terminal descriptors ..................................................................................................................97D.4 Rear terminal power connections ............................................................................................ 100D.5 CSI 2600 DIP switch settings ....................................................................................................100

Appendix E Troubleshooting ........................................................................................................ 101

Index ................................................................................................................................................103

Contents

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1 CSI 2600 Machinery Health ExpertTopics covered in this chapter:

• CSI 2600 overview

• User Guide overview

• User Guide conventions

• Technical support

1.1 CSI 2600 overviewThe CSI 2600 Machinery Health™ Expert is a portable, online analyzer that simultaneouslyand continuously monitors and records up to 24 vibration or process channels and up to 4speed inputs.

The CSI 2600 is available with one or two 6510 signal input modules. Each 6510 modulehas 12 analog channels, 2 tachometer channels, and 2 relay channels. Emerson sells theCSI 2600 as a 12/2/2 channel or a 24/4/4 channel analyzer.

The CSI 2600 comes in non-Transient and Transient configurations. A non-Transient unit isdesignated by an "M", such as A2600M, and a Transient unit is designated by "T", such asA2600T. The analog channel count is also part of the name; a 12 channel unit is designatedby the number "7", and a 24 channel unit is designated by the number "8". Available modelsare:

• A2600M7—non-Transient, 12 channel

• A2600M8—non-Transient, 24 channel

• A2600T7—Transient, 12 channel

• A2600T8—Transient, 24 channel

This manual will assume that the CSI 2600 is an A2600T8—a Transient, 24 channel system.

Use Emerson's AMS Suite: Machinery Health™ Manager software to view orbits, shaftcenter lines, Bode, polar, cascade, waveform, and spectrum plots live and simultaneously,or to archive for future reference.

1.2 User Guide overviewThe CSI 2600 Machinery Health Expert User Guide is written for Vibration Analysts,Reliability Data Collection Technicians, and Reliability Engineers who monitor rotatingmachines in a process plant environment. This user guide describes how to set up the unit,collect data, and transfer the data to AMS Machinery Manager for storage and analysis.

CSI 2600 Machinery Health Expert

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1.3 User Guide conventionsThe following conventions are used throughout this User Guide.

NoteA note paragraph contains special comments or instructions.

CAUTION!

A caution paragraph alerts you to actions that may have a major impact on the equipment orstored data.

WARNING!

A warning paragraph alerts you to actions that may have extremely serious consequences forequipment and/or personnel.

1.4 Technical supportWhen you contact Technical Support, be ready with a screen capture of the error messageand details such as when and how the error occurred.

Hardware Technical Help

Have the number of the current version of your firmware ready when you call.

Software Technical Help

Provide the software version numbers of both your Microsoft® Windows operating systemand AMS Suite: Machinery Health Manager, and your AMS Machinery Manager serialnumber. To find AMS Machinery Manager version and serial numbers, select Help > About.

Be at your computer when you call. We can serve you better when we can work throughthe problem together.

Software Technical Support

Emerson provides technical support through the following for those with an active supportagreement:

• Telephone assistance and communication via the Internet.

• Mass updates that are released during that time.

• Interim updates upon request. Please contact Emerson Technical Support for moreinformation.

Contact us

For Emerson Technical Support and Customer Service Toll Free numbers, email addresses,and hours of operation, please visit http://www.sureservice.com and select TechnicalSupport and Customer Service.

CSI 2600 Machinery Health Expert

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2 Introduction to the CSI 2600Topics covered in this chapter:

• CSI 2600 out of the box

• Optional services

• CSI 2600 monitoring requirements

• Precautions

• Safety notes

2.1 CSI 2600 out of the box

CSI 2600 front viewFigure 2-1:

Introduction to the CSI 2600

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CSI 2600 back viewFigure 2-2:


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CSI 2600 accessoriesFigure 2-3:

• CSI 4500/6500/2600 Machinery Health Monitor firmware DVD• AMS Suite Operating Manuals & Extras DVD• 1 Ethernet cable• 1 serial cable• 1 package of replacement filters• 1 standard IEC 320 C13 to NEMA 5-15P power cord• 1 3-pin screw mount connector plug• 3-piece international AC adapter kit

Optional accessories

• Sensors


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• Mounting pads

• BNC connectors

• Extension cords

Optional firmware

• PeakVue

• Modbus

Optional software

• Object Linking and Embedding for Process Control (OPC)

2.2 Optional services• Training in the Online Prediction Operation and Maintenance course and rolling

element bearing vibration.

• Remote analysis.

• Turbomachinery diagnostic training and AMS Machinery Manager transient analysistraining.

2.3 CSI 2600 monitoring requirementsThe CSI 2600 portable transient monitoring requires:

• Field wiring to installed sensors

• AC line power wiring

• Connection points (usually a buffered output panel) for cabling to the CSI 2600monitoring unit

• Computer

• CSI 2600 firmware (loaded on Online Server, downloaded into CSI 2600 monitoringunit)

• Machinery Health Manager online software

• Online Database

• Ethernet cable

2.4 PrecautionsCleaning

The CSI 2600 is dust resistant. Use a damp, clean cloth for cleaning. Do not use cleaningfluids, abrasives, or aerosols, as they could enter the device, causing damage, fire orelectrical shock.


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Avoid water

Avoid direct contact with water, wet surfaces, or condensing humidity. Keep away fromwet locations such as sinks, laundry, wet basements, swimming pools, and so on. If thedevice is subjected to these conditions, adverse operation may result. If the surface of thedevice becomes wet, allow it to dry thoroughly before operation.

Avoid damage or injury

Follow these guidelines to avoid costly damage or injury:

• Place the device on a solid, stable surface when not in use and do not place anyheavy objects on it.

• Use only accessories recommended by Emerson Process Management.

• Keep liquids and foreign objects away from your CSI 2600.

• Never operate your CSI 2600 if any liquid or foreign object has entered it.

• The enclosure should never be subjected to direct sunlight for long periods of time.

2.5 Safety notesThis document is intended as a guide only. No instructions given here are intended tosupersede any locally issued directions or safety instructions.

WARNING!

Do not operate the CSI 2600 in a hazardous area.


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3 Getting startedTopics covered in this chapter:

• Remove the CSI 2600 from the case

• Turn on the CSI 2600

• Turn off the CSI 2600

• CSI 2600 fuse access

• Data collection overview

• Data recorder modes

• Store data on a NAS hard drive

• Network configuration

• System architecture

• Access the termination board

• Connectivity

3.1 Remove the CSI 2600 from the case

CAUTION!

The CSI 2600 should be placed on a dry, level, cool surface where the vents and fans are notblocked. Avoid hot, wet surfaces and do not block the vents or fans.

NoteThe CSI 2600 cannot be used while in the case.

Procedure

Reach down along the top and bottom of the CSI 2600 and extract the device straight upfrom its case.

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Remove the CSI 2600 from the caseFigure 3-1:

3.2 Turn on the CSI 2600The CSI 2600 has two toggle switches, and both must be toggled in order to turn the uniton and off.

Prerequisites

WARNING!

Ensure that physical contact with unbuffered sensor signals will not interfere with othermonitoring or protection systems.

Procedure

1. Plug the power cord into a standard 120 - 240 VAC input. Attach one of the providedadapters if necessary.

The unit automatically senses the correct voltage.

2. Press the toggle switch located at the rear of the case to On.

3. Press the toggle switch located at the front of the case to On.

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3.3 Turn off the CSI 2600Prerequisites

Make sure that the computer has been connected long enough to allow all of the desireddata to be transferred to the computer for storage. Check the time stamps of the databeing reported in Online Watch. Once the times have progressed past the time rangeneeded, data collection can be stopped and the CSI 2600 can be powered off.

Procedure

1. Turn the toggle switch located on the front of the unit to the Off position.

After a couple seconds, the light will turn off. Wait for the light to turn off beforecontinuing with the next step.

2. Turn the toggle switch located on the back of the unit to the Off position.

3. Unplug the power cord.

3.4 CSI 2600 fuse access

CAUTION!

Turn off the power to the CSI 2600 and unplug the unit before accessing the fuses.

Two 10 A fuses for the power input are accessible through a small access panel betweenthe receptacle and the power switch. The access panel can be opened with a flatheadscrewdriver.

Fuse accessFigure 3-2:

The AC power input is located on the unit's faceplate.

A. Fuse access panel

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3.5 Data collection overviewThe CSI 2600 is a continuously monitoring online system. Once configured, it will collectboth periodic predictive data (Trend, Spectra, and Waveform snapshots, multiplexed twochannels at a time) and Transient measurements (continuous unbroken waveforms forextended periods on up to all 24 channels). Predictive data can be stored in an AMSMachinery Manager database. Sections of the transient waveforms can also be extractedinto archives either on-demand or based on alarm events.

For the Transient channels, the CSI 2600 continuously stores waveform measurements ona Hard Disk Drive (HDD). This can be either the internal 80 GB HDD or an external NASdrive (up to 250 GB). When the drive fills up, the system will begin overwriting the oldestmeasurements in a First In First Out (FIFO) manner.

Data is stored at a rate of approximately 40 MB per hour per channel. The followingmethod can be used for estimating the amount of time that data can be streamed to theHDD before it begins to FIFO. First determine the number of channels that will becommissioned for Transient operation; then use this equation:Storage Time (in hours) = HDD size / (number of Transient channels x 40 MB/hr).

For example, consider a pump monitoring system which has a total of 14 sensors. Thiscould include 4 pairs of radial shaft vibration probes, 2 thrust probes, 1 case expansionsensor, 1 eccentricity sensor, and 2 horizontal accelerometers. In addition to collectingperiodic prediction data, the 8 shaft vibration probes are also commissioned for Transientdata collection.80,000 MB / (8 channels x 40 MB/hr) = 250 hours (approximately 10 days)So, the internal HDD will store data for approximately ten days before starting to FIFO.

The CSI 2600 is both a continuous monitoring system and a portable monitoring system. Itcan be moved from one piece of equipment to another, with data from each piece storedin separate databases. See Section 6.10 for more information.

CAUTION!

Changing databases will reinitialize the Transient HDD, which eliminates all stored data.Extract any data before changing databases.

3.6 Data recorder modesData collection to CSI 2600 internal memory

When the CSI 2600 is running and the computer is disconnected, the unit runs in DATrecorder mode, optimized for turbomachinery transient data. Waveforms from up to 24channels, including tach striping, are recorded continuously and simultaneously. If all 24channels are streaming transient data, the internal 80 GB HDD will store approximately 90hours of data before it begins to FIFO.

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With the computer disconnected, the periodic predictive data is also buffered in the CSI2600’s internal RAM. The amount of time it will take to fill up the CSI 2600’s internal RAMdepends on how periodic predictive data storage settings are configured in the database.This data will also begin to FIFO when the memory buffer is full.

Data extraction from the CSI 2600

If the computer is reconnected while the CSI 2600 is in DAT recorder mode, any bufferedperiodic predictive data that has not been deleted by the FIFO process will automaticallybe transferred from internal memory to the database. Transient data will only be written tothe database if a transient alarm event has occurred and the associated data has not beendeleted by the FIFO process. Each transient channel can transfer a configurable amount ofdata (up to 30 minutes before and after) when a predefined transient alarm event hasoccurred.

When the computer is reconnected, portions of recorded data can be extracted ondemand with AMS Machinery Manager Vibration Analysis. Field-based processing ofmultiplexed predictive data continues as usual while Vibration Analysis extracts data.

CAUTION!

If the computer is not connected, data may be lost or overwritten.

3.7 Store data on a NAS hard driveThe default streaming location is the internal hard drive. However, an external NAS drivecan be used as an alternative transient streaming location. The CSI 2600 supports NASdrives up to 250 GB in size. You can use a NAS hard drive as the primary drive for transientstorage or as a failover drive.

Prerequisites

Connect the NAS drive to the same port that is used to connect to the computer. The NASdrive must be capable of continuous write speeds of >20 MB/s, 100 Base-T minimum, andrated for a 100% duty cycle.

Procedure

1. In the AMS Machinery Manager Online Configuration tree structure, click one of theunits to display the Unit Properties dialog.

2. Configure values in the External Network Folder Specifications field.

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Online Configuration—External Network Folder SpecificationsFigure 3-3:

External Network Folder Specifications dialog fieldsTable 3-1:

Field Values Explanation

UNC Path (variable) Specifies the to the NAS drive folder where the unitshould stream transient data.

Allowed Drive Space 1–250 GB Specifies the limit for transient data on the NASdrive. The data will begin to FIFO when it reachesthis limit.

Use Drive Space As Primary Indicates that the NAS drive is to be used as theprimary streaming location (replacing the internalhard drive.

Failover Indicates that the NAS drive is to be used as a fail-safe location in the event that the internal harddrive fails.

Credentials Username and Password Specifies the username and password that willaccess the NAS drive folder named in UNC Path.

Example: Storage

If a 250 GB NAS drive is storing data from 24 transient channels, then it can storeapproximately 260 hours of data before it begins to overwrite the oldest measurements. Ifonly 12 channels are streaming data, about 520 hours can be stored.

3.8 Network configurationIP addresses are unique addresses that systems on a network use to communicate witheach other.

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Example CSI 2600 system IP addressesTable 3-2:

CSI 2600 Main Processor IP 192.168.0.10

CSI 2600 Transient Processor IP 192.168.0.11

Computer IP 192.168.0.1

Notes

• The IP addresses shown are defaults. If two or more systems will be used, each should begiven a unique IP address.

• IP addresses should be given subnet masks. Transient extraction may fail without them. See Section 5.7.6 for information on specifying subnet masks.

The computer's Ethernet port is connected to the CSI 2600. The port has an address. TheCSI 2600 has two processing boards, both of which communicate using the same physicalEthernet connection on the CSI 2600 front panel. These boards have IP addresses that arestored in non-volatile memory (memory that does not get cleared when you turn the unitoff). For a CSI 2600 system to communicate:

• the IP address of the computer must match a value stored in non-volatile memory ineach CSI 2600 processing board.

• the IP address of the CSI 2600 Main Processor board must match a value listed inAMS Machinery Manager software, which is associated with the database in use.

In short, the CSI 2600 must “know” its server address, and the computer must “know” theIP address of any CSI 2600.

3.9 System architecture

3.9.1 CSI 2600 online database diagramThe structure of an online database is designed to mirror the structure of the equipmentbeing monitored. The database structure for prediction processing diagram shows therelationships of the various elements of an online database.

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Online database diagramFigure 3-4:

Collection criteria• Analysis Parameter (AP) Set—Defines a particular way to collect spectral data, and

specifies:

- the number of lines of resolution.

- any averaging modes and windowing.

- whether to be order-based.

- what FMax to use.

- what parameters are to be collected.

• Alarm Limits (AL) Set—Each AL Set is associated with a specific AP Set. There may bemultiple AL Sets defined for any given AP Set to accommodate changing monitoringconditions. The alarm limit definition determines when alarms occur, data is stored,and output relays are set.

• Predicate—A collection predicate is an expression that compares the conditions ofvibration levels, input relay states, and/or machine speeds to determine when datais collected and transient auto-archives are extracted.

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Online storage logical hierarchy• Area—A user-defined grouping of equipment. An area often corresponds to a

building or section of a process line within a plant.

• Equipment—A group of coupled devices that logically should be monitoredtogether. Most often a machine train is made up of a driver component (such as amotor) and one or more driven components (such as a pump or fan).

• Components—A specific, single asset to be monitored, possibly with multiplesensors. Usually a driver or driven piece of machinery. Motors, engines, turbines,pumps, and fans are examples of components.

• Measurement Points—Corresponds to a single physical sensor. A Measurement Pointgroups together all the data from all the collections that have been defined for aparticular sensor. Any Gross Scan data collected on the sensor and reported forstorage is logically associated with the Measurement Point in the database.

• Data Collection Sets (DCS)—The DCS is a single collection of data on a singleMeasurement Point. Multiple DCSs allow multiple collections on a singleMeasurement Point. The DCS combines a particular predicate (when to collect),with a particular AP Set (what and how to collect, including parameter bands), and aspecific AL Set (alarm set points).

Physical hierarchy• CSI 2600—The physical monitoring unit.

• Signal Channels—An AC vibration or DC process input.

• Tachometer Channels—A speed measurement input.

• Digital I/O Channels—A discrete relay, Input or Output.

CSI 2600 field wiring

In addition to predictive monitoring, the CSI 2600 is also a portable transient monitoringsystem, which means in most applications it is being connected to already installedsensors. Portable transient monitoring is different from a fixed, permanently connectedsystem. For example:

• The portable application includes actions of connecting and disconnecting cablesbetween the CSI 2600 monitoring unit and installed modules or even junctionboxes. It is critical to ensure that these actions do not interfere with signals in such amanner that any permanently installed monitoring systems interpret temporarysignal fluctuations as trip conditions. This is not a concern when connecting tomodule buffered outputs.

• Modules may condition the input signal and present a modified version to their ownoutput connections (which are the input connections to the CSI 2600). For instance,some modules connect to an eddy current sensor which provides a DC outputequivalent to gap voltage (usually about -10 V) and an AC voltage equivalent tovibration (millivolt signal). These modules are configured or programmed to providea version of the input signal, at an output connection. The output signal could be a0 – 10 V version of the input.

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An analyst must know the sensitivity and offset of signals connected to the CSI 2600,which may be the same (or different) as signals connected to existing modules. An analystmust also know if the CSI 2600 connections are to buffered or unbuffered field wiring ormodule outputs.

3.10 Access the termination board1. At the bottom of the rear panel, loosen the thumbscrews by hand.

WARNING!Close the rear panel before powering the CSI 2600.

2. To lock the rear panel in the open position, lift the panel to an almost horizontalposition and gently push down near the top center of the panel (as shown).

Termination boardFigure 3-5:

3. Toggle the DIP switch to the left to turn off sensor power, or to the right to turn iton.

The set of four DIP switches on SW1 controls sensor power for channels 1–4. Sensorpower for the subsequent channels is controlled by the DIP switches on SW2, SW3,SW5, SW6, and SW7.

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3.11 ConnectivityThe CSI 2600 monitoring unit consists of:

• An AC power connection (110–220 V, 50/60 Hz)

• An Ethernet connection

• Signal connections for 1–24 sensors

• Tachometer connections for 1–4 sensors

• Digital I/O relay connections for 1–4 relays

• System power status LEDs

• An attached cooling fan

3.11.1 Power supplyPower input: 120–240 VAC, 50–60 Hz input, auto-sensing.

• AC power connection has an IEC 320 C13 receptacle

• North American 3-prong plug (NEMA 5-15P) is provided

• Unit may be powered with either 110 V / 60 Hz or 220 V / 50 Hz input power

• No internal switches need to be adjusted to select power type

• 80 W consumption

NoteA 500 W UPS is recommended. The quality of the power provided to the CSI 2600 is very important.Although the CSI 2600 contains input protection and some degree of line conditioning, it isimportant to provide the unit with clean power when ground isolated from the productionequipment.

3.11.2 Ethernet portsUse the NIC port to connect the CSI 2600 to the LAN.

Use the Hub port to connect the CSI 2600 directly to the computer.

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Ethernet portsFigure 3-6:

The NIC and Hub ports are located on the unit's faceplate.

3.11.3 Channel connectionsThe CSI 2600 offers up to 24 sensor channels. The connections are made through the BNCconnectors on the rear of the CSI 2600.

In addition, the CSI 2600 offers up to 4 tach channel connections, up to 4 digital relaychannel connections, and 1 Ethernet HUB and 1 NIC.

The CSI 2600 can accept any sensor type with AC component 10V pk-pk and DCcomponent < +/-24 V, AC+DC not to exceed +/-24 V. Accelerometers can be powered bythe CSI 2600 system’s power supply when sensor power is enabled via the DIP switches onthe termination panel, accessible through the rear panel. Displacement probes can bepowered by the auxiliary -24 VDC power supply. The output for this -24 VDC power supplyis on the rear of the CSI 2600.

Tachometers should provide 1/rev pulses of >0.5V pk-pk with tach pulse 2x noise.

WARNING!

Make sure that the sensor power is disabled when connecting to a protection system withunbuffered BNC outputs.

3.11.4 4-channel relay inputs and outputsThe CSI 2600 includes up to 4 I/O relay connections that provide optically isolated digitalinputs or dry contact outputs. Inputs can be between 5 V and 24 VDC. Outputs are limitedto 24 VDC @ 0.5 A.

The 6510 Signal Input module is a component that connects to the unit's faceplate, andallows a combination of sensor and relay types in one module. Each I/O relay channel onthe 6510 Signal Input module contains both input and output hardware. The relays areconfigurable as either input or output relays, with a DIP switch (SW1) on the circuit board.A relay channel that is configured in software cannot be utilized unless the correspondingDIP switch is set to the correct position. The firmware will detect the DIP switch state atstartup and generates a flag in the HyperTerminal(1) session if the software configurationdoes not match the DIP switch setting.

(1) See Section 5.7 for more information on terminal emulators like Hyper Terminal.

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The DIP switches are used to protect a user input device from inadvertently being shortedby a relay output configuration. Set the corresponding DIP switch to the On position foroutput relays, and to the Off position for input relays. The factory default state of the DIPswitches is Off (Input). DIP switch 1 is for the first relay channel and DIP switch 2 is for thesecond relay channel.

The shelf-state of the output relays is normally open, meaning that when the power to theunit is disconnected, the relays are open. During operation of the unit, the relays aretypically closed until activated by an alarm, but they can be configured either way.

The following are usage examples for an online monitoring system:

• (input) Transient event indicator, perhaps from a switch, DCS, external module

• (output) Bad/failed sensor indication

• (output) Alarm level indication

• (output) Speed level indication

• (output) Radial Trip Predicate state

• (output) Axial Thrust Predicate state

In most applications, the CSI 2600 will connect to buffered outputs of a protection system.These modules normally have relay outputs which indicate alarm levels, or bad/failedsensors. However, the CSI 2600 relays are different in that:

• A CSI 2600 alarm relay state may be based upon either overall vibration value (i.e.,the attached module) or Analysis parameter signal level (i.e., energy at 1x turningspeed, energy at 2x turning speed).

• All, some, or one of the alarm indicators may be mapped to the same CSI 2600alarm relay output. In other words, all of the “Bad/Failed sensor” signal levels may beinternally connected to a single relay. All of the “High alarm” signal levels may beinternally connected to a single relay.

Radial Trip and Axial Thrust predicates are special methods of configuring voting logic forrelay closures, and are explained in Emerson Machinery Health Manager manuals such asthe Online Software guide (MHM-97460). These are innovations provided by the CSI 2600system, which have value in turbo machinery applications.

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4 Hardware configuration: overviewTopics covered in this chapter:

• Gross Scan monitoring

• Spectral Scan

• Transient data capture

• Install a module

• Remove a module

• 6560 Processor module

• CSI 2600 signal inputs

• 6510 Signal Input module

• Mounting accelerometers

• Mounting tachometers

• Eddy current sensors

The 6560 Processor Module, in combination with the 6510 Signal Input Module, is a multi-channel, multi-tasking, multi-processor data acquisition system primarily intended formonitoring heavy industrial rotating machinery. Typical signal inputs are dynamic ACmachine vibration signatures from accelerometers, velocity probes, or eddy currentsensors. These signals include two components: the dynamic AC component, whichrepresents machine vibration, and a DC component, which represents the sensor biaslevel. In the case of an eddy current sensor, the DC component represents the gap, oraverage distance between the probe tip and the machine shaft. Other signal inputs includeprocess signals; these are DC parameters such as temperature or pressure.

Tachometer inputs are used to determine machine speed. These tachometer signals aretypically generated from an eddy current sensor or passive magnetic sensor positioned ata machine shaft keyway or gear, producing a pulse train (not necessarily 1x machinespeed) representing the machine phase and running speed.

Discrete inputs represent machine states such as running, off, and starting. These inputsare used to control or modify the data acquisition based on machine state. Common statecontrol inputs are relay closures or machine RPM. AC or DC signal levels can also be usedfor state control.

4.1 Gross Scan monitoringGross Scan monitoring includes:

• the acquisition of the overall level of the dynamic AC vibration signal, typically theRMS value of the signal.

• the DC sensor bias level.

• the measurement of a DC process signal.

Hardware configuration: overview

MHM-97453, Rev 1 23

All these signal inputs are DC values (the RMS value is a DC value proportional to theoverall energy content of the AC signal). The Gross Scan inputs are multiplexed into a fastsuccessive approximation ADC controlled by the 6560 Processor module. Gross Scanmonitoring measures all input channels AC+DC twice per second. When the Transientoption is included, true waveform peak-to-peak may be included in Gross Scanmonitoring.

4.2 Spectral ScanSpectral Scan is defined as the acquisition and analysis of dynamic AC signals only. Thesignals are acquired, two channels at a time (referred to as CHX and CHY), with a dualchannel delta-sigma ADC controlled by the system DSP. The DSP performs analysis of theacquired time waveforms and transmits the results to the CPU host processor.Preprogrammed groups of Spectral Scan measurement parameters (AP Sets) may beassigned to specific machine state conditions to tailor data acquisition to specific machineoperational states.

4.3 Transient data captureTransient data capture is the acquisition of continuous time waveforms of dynamic ACsignals. Transient data is captured in parallel for all channels. Other data stored along withthe Transient data include Gross Scan data captured once per second, tach pulse records,and acquisition timestamps. The Transient data is stored on hard disk, and is available forreal-time analysis via Ethernet.

4.4 Install a module1. Line up the guide rails and push the module into the slot until fully seated.

2. Tighten the mounting screws.

4.5 Remove a module1. Loosen the mounting screws.

2. Push outward on the handles to eject the module from the backplane connectors.

3. Pull the module from the slot by the handle.


24 MHM-97453, Rev 1

Remove a moduleFigure 4-1:

Use the handles to remove modules.

4.6 6560 Processor moduleThe 6560 Processor module provides all data acquisition, data storage, and datacommunications functions for the CSI 2600. The 6560 is capable of up to 24 simultaneous,continuous waveform measurements for detailed Spectral analysis, up to 24 RMS and DCvalues for Gross Scan measurements, up to 4 tachometers for machine speedmeasurement, and up to 4 discrete state inputs.

Gross Scan values, tachometer values, and digital input states may be combined logicallyto determine machine operating state, which may be used to define specific dataacquisition states. The system can be configured to transmit and store data on either timeinterval or based on the amount of change of the data values.

The processor module provides 2 100Base-T Ethernet ports and one RS-232 serial port forsystem communications and diagnostics. Additional connections are available for thecalibration signal and a dry contact SPDT SysFail relay. This relay is energized when theProcessor CPU successfully boots. On a CPU failure or power loss, the relay will de-energize.


MHM-97453, Rev 1 25

6560 Processor moduleFigure 4-2:

4.6.1 Transient DaughterboardThe Transient Daughterboard adds the capability for parallel, continuous time waveformacquisition on all channels. All collected time waveform data, along with Gross Scan dataand up to four tachometer pulse records is stored on an internal hard drive, which providesapproximately 80 minutes per GB of storage.

The Transient Daughterboard can also stream data via Ethernet to analysis applications innear real time, without affecting data collection or on-board data storage.

While collecting time waveforms and tachometer pulses, the Transient Daughterboardcontinuously calculates the peak-to-peak value of each channel's waveform. Whenconfigured, this value may be sent to the 6560 Processor module for use as the Gross Scaninstead of the RMS value produced by the 6510 Signal Input module.


26 MHM-97453, Rev 1

The hard drive used on the Transient Daughterboard is specially rated for continuousoperation. This drive should be replaced annually. In emergencies, any 2.5 in. parallel IDEdrive may be used temporarily, but these drives are not generally rated for continuousoperation.

When installing the Transient Daughterboard on the 6560 Processor module, make sure allfive mating connectors are fully engaged, and then install all six mounting screws.

Transient Daughterboard PCB mounted on Processor moduleFigure 4-3:

A. Mounting screw positionsB. Transient Daughterboard hard drive

Replace the Transient Daughterboard hard drive

Transient Daughterboard hard drive insetFigure 4-4:

A. Hard drive mounting screwsB. Ribbon cable


MHM-97453, Rev 1 27

Procedure

1. Remove the four hard drive mounting screws.

2. Gently remove the hard drive ribbon cable from the hard drive, and then remove theold hard drive.

3. Install the new hard drive in the bracket.

CAUTION!Do not over tighten the screws.

4. Replace the ribbon cable. Take care to line it up correctly.

Format the hard drive for the Transient Daughterboard

Before the new hard drive can be used, it must first be formatted by the TransientDaughterboard.

Prerequisites

• Power on the system.

• Ignore any hard drive error messages produced by the Transient Daughterboard onthe HyperTerminal monitor.

• When the system has booted, use the DHM_III program (located in the C:\inetpub\ftproot\bin\Tools directory) to format the hard drive.

Procedure

1. Launch DHM_III.exe.

2. Select the Transient menu.

3. Click Format Hard Drive.

Postrequisites

When the drive has been formatted, reboot the unit. Ignore any hard drive error messagesproduced by the Transient Daughterboard on the HyperTerminal monitor.

When the POST process is complete, the firmware will automatically prepare the harddrive with the Transient File System. This process may take up to an hour.

Reboot the unit. The boot process should now complete normally with no hard drive errormessages. If configured, Transient data collection should begin, indicated by a flashinghard drive indicator on the Processor front panel.

4.7 CSI 2600 signal inputsThe CSI 2600 is designed to receive voltage signals directly from sensors or from sensorsupport modules. The online database will store the collected sensor signal in theappropriate engineering unit, such as acceleration, velocity, displacement, and pressure.


28 MHM-97453, Rev 1

Signals from 4-20 mA devices, RTDs, thermocouples, and other specialized sensors requireexternal conditioning electronics that convert the sensor signal into a voltage signal theCSI 2600 can accept on its BNC input panel. The CSI 2600 can supply power topiezoelectric sensors from the BNC connection.

The CSI 2600 has 4 BNCs for tachometer inputs on the rear panel. The tachometer BNCinputs accept voltage signals only and do not furnish tachometer power.

When the CSI 2600 is in transient data collection mode, not all signals connected to a CSI2600 need to be designated as transient. But since the Transient system is used to detectunexpected events using its continuous monitoring capability, it's best to designate everychannel to be transient to make sure a special event is not missed.

4.8 6510 Signal Input moduleThe 6510 Signal Input module combines the features of Signal Input, Tachometer Input,and I/O Relays to allow a combination of sensor and relay types in one module.

The 6510 provides 12 channels of vibration or process sensor inputs, 2 channels oftachometer sensor inputs, and 2 optically-isolated I/O relay channels.

See Section A.2.2 for specific calibration information.


MHM-97453, Rev 1 29

6510 Signal Input moduleFigure 4-5:

4.8.1 Vibration signal inputsThe vibration sensor types include accelerometer, passive velocity, active velocity, anddisplacement. The Signal Input module will also accept non-specific AC or DC inputs fromany source that conforms to the input range limits.

The vibration inputs provide the following programmable functions for each channel:Input Attenuator /1, /2, Gain x1, x10, integrator on/off. In Table 4-1, the combination ofinput attenuator and gain setting provide four input range combinations.

Signal input module input rangesTable 4-1:

Attenuator Gain Input Range +/-

/2 x1 10.0 V, 100 g, 100 ips, 50 mil


30 MHM-97453, Rev 1

Signal input module input ranges (continued)Table 4-1:

Attenuator Gain Input Range +/-

/1 x1 5.0 V, 50 g, 50 ips, 25 mil

/2 x10 1.0 V, 10 g, 50 ips, 5 mil

/1 x10 0.5 V, 5 g, 5 ips, 2.5 mil

The integrator allows acceleration signals to be converted to velocity.

The 6510 Signal Input module selects 2 of the 12 vibration channels at a time and routesthem to the Processor module for spectral analysis. RMS-to-DC conversion is performed onall 12 channels. The RMS and DC signals are routed to the Processor module for Gross Scancollection.

The Transient Filter Board is required for Transient data acquisition.

To measure 4-20 mA signals, add a resistor across the channel input. A typical value is 250ohms, which converts 4-20 mA to 1-5 V. Maximum series resistor value is 1000 ohms.

4.8.2 Tachometer inputsThe Tachometer inputs allow measurement of two pulse tachometer sources per module.Tachometer sensor types may include, but are not limited to: eddy current sensor, Halleffect sensor, or TTL pulse type from various sources.

The Tachometer Input module features either fixed voltage trigger or “adaptive”automatic triggering. Triggering parameters may be set independently for eachtachometer sensor input.

An input gain selection of x1 or x5 may be selected for each channel. A gain of x5 isrecommended for tachometer inputs smaller than 1 V pk-pk. If the x5 input gain is used,care should be taken to make sure that the input signal remains within +/-24 V, includingany sensor bias or gap voltage.

4.8.3 I/O relay channelsEach 6510 Signal Input module has two I/O relay channels that provide optically isolateddiscrete inputs or dry contact outputs. Inputs can be between 5 V and 24 VDC. Outputs arelimited to 24 VDC @ 0.5 A.

NoteAC relays are not provided.


MHM-97453, Rev 1 31

Signal Input module PCBFigure 4-6:

A. I/O relay DIP switches

Each I/O Relay channel on the 6510 Signal Input module contains both input and outputhardware. The relays are configurable as either input or output relays, with a DIP switch(SW) on the circuit board. A relay channel that is configured in software cannot be usedunless the corresponding DIP switch is set to the correct position. The firmware will detectthe DIP switch state at startup and generates a flag in the HyperTerminal session if thesoftware configuration does not match the DIP switch setting. The DIP switches are usedto protect a user input device from inadvertently being shorted by a relay outputconfiguration.

Set the corresponding DIP switch to the ON position for output relays, and to the OFFposition for input relays. The factory default state of the DIP switches is OFF (Input). DIPswitch 1 is for the first relay channel and DIP switch 2 is for the second relay channel.

The shelf-state of the output relays is normally open, meaning that when the power to theunit is disconnected, the relays are open. While operating the unit, the relays are typicallyclosed until activated by an alarm, but they can be configured either way.


32 MHM-97453, Rev 1

4.8.4 Transient Filter BoardThe Transient Filter Board provides parallel anti-aliasing filters for the signal channels onthe Signal Input module. Either one or two Transient Filter Boards may be used toconfigure either a 12- or 24-channel Transient System.

When installing the Transient Filter Board on the Signal Input module, make sure bothmating connectors are fully engaged, then install all six mounting screws.

Transient Filter Board PCB mounted on a Signal Input moduleFigure 4-7:

A. Mounting screw positionsB. Transient Filter BoardC. I/O relay DIP switches

4.9 Mounting accelerometers

4.9.1 Handling accelerometersGeneral purpose accelerometers are susceptible to mechanical shock. Take precautionwhen handling sensors. When magnetically mounting sensors, it is possible to generateshock loads that will damage sensors and void the manufacturer’s warranty. To preventdamage, gently rock magnetic sensors into place.

WARNING!

Do not drop, hammer, or impact the sensor housing before, during, or after installation.


MHM-97453, Rev 1 33

CAUTION!

Do not exceed specified torque when tightening stud-mounted accelerometers. Over-tightening accelerometers will damage sensing elements and void the manufacturer’swarranty.

Although the integral cable has built-in strain relief, avoid excessive pulling force duringcable pulls. Secure cable to the machine near the point of sensor installation.

CAUTION!

Do not exert more than 5 lbs pull force directly on sensor/cable connection during wire pulls.

If sensor mounting occurs before cable is pulled in conduit or raceway to junction box,leave cable bundled and secured to the machine. Sensor cable cannot be stepped on orseverely kinked, or permanent signal degradation will occur. Cable bundle should also notbe placed in such a manner that it will cause undo strain at the sensor/cable connection.

4.9.2 Tools and suppliesMounting tools

• Drill

• Spot face or end mill tool

The spot face tool attaches to a standard electric drill and provides a machined surface atleast 1.1 times greater than the diameter of the sensor. At the same time, the spot facetool also drills a pilot hole that can then be tapped for the stud mounted sensor.

The spot face tool can be purchased from Emerson or a spot face tool with similarcharacteristics may be substituted as required. Contact your local sales representative forassistance.

Spot face or end mill toolFigure 4-8:

For epoxy mounting, the following are also necessary:

• 2-part epoxy (e.g. Loctite Depend [Emerson P/N A92106] or comparable)

• A212 Mounting Pads


34 MHM-97453, Rev 1

• (Optional) Grinder – to create a sufficiently flat mounting surface

Accelerometer attachment tools and supplies

• 40-200 in. lb torque wrench with 1/8 in. hex bit

Suggested vendor: Grainger

Part number: 4JW57

Description: 3/8-in. drive in. lb torque wrench. Any torque wrench with a range of 40to 70 in. lb and less than 5 in. lb increments can be substituted.

• 1/4 in. 28 taps and tap handle

• 9/16 in. open-end wrench

• 1/8 in. hex Allen key

• Wire brush

• Plant-approved cleaner/degreaser

• Plant-approved semi-permanent thread locker (e.g. Loctite)

4.9.3 Surface preparation: stud mount

NoteThe mounting location must provide a flat surface, 1 in. in diameter. If this is not possible, analternative mounting procedure must be used. Do not proceed; contact the project manager.

NoteThe mounting location must provide a case thickness exceeding 0.4 in. If this is not possible, analternative mounting procedure must be used. Do not proceed; contact the project manager.

Stud mount1. Prepare the spot face or end mill tool by setting the drill bit depth to a minimum of

0.325 in. (325 mils).

2. Using a wire brush and plant-approved cleaner, clean and degrease the surface area.

3. Keeping the spot face/end mill tool perpendicular to the machine surface, drill intothe mounting location until the surface is smooth to the touch with no noticeableirregularities. This may require the spot face tool to remove as much as 0.04 in. (40mils) or more from the surface.

NoteIf the spot face is not uniform on all sides, this is an indication that the spot face tool is notperpendicular to the mounting surface and the resulting surface will not allow the sensor tobe mounted properly.

4. Using 1/4 in.-28 tap set, tap a pilot hole to a minimum depth of 0.25 in. (250 mils).

Refer to Figures Figure 4-9 through Figure 4-11 for illustrations on the stud mount method.


MHM-97453, Rev 1 35

Correct (left) and incorrect (right) milling processesFigure 4-9:


36 MHM-97453, Rev 1

Milling process for sensor mountingFigure 4-10:

This spot facing should result in a uniform seat being created.


MHM-97453, Rev 1 37

Tapping a pilot holeFigure 4-11:

4.9.4 Surface preparation: epoxy mount

NoteThe mounting location must provide a flat surface, 1 in. in diameter. If this is not possible, analternative mounting procedure must be used. Do not proceed; contact the project manager.

Epoxy mount1. If the equipment surface has a radius of curvature that is less than 4 in., grind a flat

surface approximately 1/2 in. diameter.

2. Using the wire brush and plant-approved cleaner, clean and degrease the surfacearea.

3. Using a 2-part epoxy (such as Emerson P/N A92016), spray the activator onto themounting surface.

4. Place a light coat of epoxy on the surface of the mounting pad (such as Emerson P/NA212) and hold firmly against the machine spot face surface for 1 minute.

If the adhesive does not set within 1 minute, it is an indication that too much epoxyis applied or that the mounting surface is not prepared properly. Repeat steps 2through 4.


38 MHM-97453, Rev 1

4.9.5 Install mounting studsFor use when installing A911 mounting stud or A0322 Quick-Connect base.

Procedure

1. Using a plant-approved degreaser, remove any lubricating fluid used during thetapping process.

2. Using a plant-approved epoxy, rub a small amount of epoxy onto spot face.

3. Using a 0.25 in. allen wrench, loosely screw a mounting base into the mountinglocation.

4. Using a torque wrench with a 0.25 in. hex bit, torque to 7-8 ft-lbs.

If the mounting base is not seated against the spot face after torquing, the tap wasnot deep enough.

5. If the sensor will not be mounted immediately, cover exposed quick-connectthreads to prevent contamination. Industrial tape is recommended.

A911 Quick-ConnectFigure 4-12:

4.9.6 Mount accelerometersPrerequisites

NoteIf you are not ready to pull cables, do not mount sensors on the machine. If it is necessary to mount asensor, the bundled cable must be secured to the machine and protected from damage.

Procedure

1. Using a plant-approved cleaner/degreaser, remove any lubricating fluid used duringthe tapping process and clean the mounting stud threads.

2. Rub a small amount of semi-permanent thread locker onto the mounting location.


MHM-97453, Rev 1 39

3. Place the sensor onto the mounting stud and hold it to create the least amount ofcable strain and cable exposure. While holding the sensor, hand-tighten the 9/16 in.captive nut and use a torque wrench with the 9/16 in. open end to finish tighteningto 50–60 in-lbs.

4. Secure sensor cable to the machine approximately 4–5 in. from the mountinglocation using an appropriately sized cable clamp. Do not exceed bending radius of2.8 in.

Sensor installation for industrial swivel mountsFigure 4-13:


40 MHM-97453, Rev 1

4.9.7 Mount accelerometers without Quick-ConnectPrerequisites

NoteIf you are not ready to pull cables, do not mount sensors on the machine. If it is necessary to mount asensor, the bundled cable must be secured to the machine and protected from damage.

Procedure

1. Using a plant-approved cleaner/degreaser, remove any lubricating fluid used duringthe tapping process and clean the mounting stud threads.

2. Rub a small amount of semi-permanent thread locker onto the mounting location.

3. Hand-tighten the mounting stud into the sensor housing, and use a 9/16 in. torquewrench to tighten the sensor and mounting stud into mounting location to 5 ft-lbs.

4. Secure sensor cable to the machine approximately 4–5 in. from the mountinglocation using an appropriately sized cable clamp. Do not exceed bending radius of2.8 in.

CAUTION!

Mount the sensor to the machine before terminating or securing cable to the machine.

4.10 Mounting tachometers

4.10.1 Handling passive magnetic tachometersThe passive magnetic tachometer is installed near moving machinery—typically a rotatingshaft. Observe clearances between the sensor and the target, and observe cableclearances.

CAUTION!

The tachometer can be damaged if proper clearance is not maintained between the sensor andthe actuator. Follow installation procedures to set proper clearance.

4.10.2 Tools and suppliesThe included mounting bracket and locking nut are required to install passive magnetictachometers.

The universal mounting bracket will fit a variety of applications. If the included bracket willnot work, then the contractor will have to fabricate a custom bracket.


MHM-97453, Rev 1 41

Mounting bracket for a passive magnetic tachometerFigure 4-14:

4.10.3 Actuator choice: guidelinesActuator dimensions

Some passive magnetic tachometers are designed to be used with a key meeting thefollowing minimum specifications:

Key dimensionsFigure 4-15:

Key dimensionsTable 4-2:

A Dimension of top of tooth >0.15 in.

B Height of tooth >0.5 in.


42 MHM-97453, Rev 1

Key dimensions (continued)Table 4-2:

F Gear thickness >0.3 in.

If the chosen actuator has a dimension that must be greater than 0.5 in., round the edgesof the actuator to allow the sensor to be as close as possible to actuator.

Modifying large actuatorsFigure 4-16:

Actuator material

The actuator must be made of a metallic material with a high permeability. Ideal actuatorsare soft iron, cold-rolled steel, and #400 stainless steel.

4.10.4 Mount the sensor bracket1. Turn the machinery shaft so that the actuator is at the mounting location.

2. Place the sensor in the mounting bracket and screw the sensor into the bracket,exposing an equal amount of thread on the back and front of the mounting bracket.

3. Place the sensor/bracket assembly into the mounting location and center the sensorpole piece over the actuator so the pole piece touches the actuator. Mark the holelocations on the bracket.


MHM-97453, Rev 1 43

4. Drill and tap hole locations for an appropriately sized bolt to fit a 0.25 in. opening onthe mounting bracket.

5. Secure the bracket to the mounting location and torque to bolt specifications.

Mounted passive magnetic tachometerFigure 4-17:

4.10.5 Mount tachometers1. Screw the locking nut onto the sensor and thread completely onto the sensor.

2. Screw the sensor into the mounting bracket until the sensor pole piece contacts theactuator.

3. Back off the sensor 1 full turn.

4. While holding the sensor in place, thread the locking nut against the mountingbracket. Torque to 15 ft-lbs.

5. Slowly turn the shaft and confirm that the actuator does not contact the sensor.

If sensor is contacting the shaft, loosen the lock nut and repeat steps 3 and 4.

6. Run the machinery at full speed and confirm that the sensor does not contact theactuator. Let the machine reach normal operating temperature and run through alloperational speeds.

7. Observe the machinery during coastdown, and confirm that the sensor does notcontact the actuator.

8. Cover exposed connector threads with the included protective cap to preventcontamination.

4.11 Eddy current sensorsEddy current sensors are also supported.

Installation instructions for eddy current sensors PR6422–PR6426 and probe driversCON011–CON041 are part of the manuals packaged with your sensors.


44 MHM-97453, Rev 1

5 Software configurationTopics covered in this chapter:

• System overview diagram

• Connect the CSI 2600 to the network server

• Configuration overview

• Install AMS Machinery Manager

• Configure the computer's IP address

• Configure the FTP server to download firmware

• Configure boot parameters with a terminal emulator

• Add an Online Server to RBM Network Administration

5.1 System overview diagram

System overview diagramFigure 5-1:

• Network Server—Service responsible for handling the user's access to the variousprograms within the AMS Machinery Manager software.

• Online Watch (O_watch)—Graphic interface that allows:

- viewing of data sent to the server by the CSI 2600

- management of transient acquisition and auto-extraction

Software configuration

MHM-97453, Rev 1 45

- adjustment of alarm levels

- on-demand data acquisition

• Online Configuration (O_config)—Program that allows the creation and modifyingof databases for use with the online system, along with system commissioning.

• Vibration Analysis (Diagnostics)—Application that allows the user to request andsave transient data and view live streaming data. It provides a variety of analysisfunctions necessary for analyzing the data generated by the CSI 2600.

• CSIMtDbMgr Service—Handles most of the reading and writing operationsperformed on databases stored on the server. It also indexes and verifies theintegrity of databases.

• Online Server (O_server)—The central process service which handles all predictiveactivity on the online system. It is responsible for processing requests from theclient, sending configuration information to the CSI 2600, and receiving data fromthe CSI 2600.

• MHM Remote—Service that handles transient data generated by the CSI 2600, anddatabase access required by the Vibration Analysis program.

• CSI 2600—Hardware portion of the monitoring system; a portable unit that isconnected to the server through Ethernet.

• IIS FTP—Microsoft's IIS includes an FTP server which needs to be installed to allow theCSI 2600 to load firmware from the server.

• Firmware—The firmware consists of two files which are loaded from the computerduring the boot up of the CSI 2600. This allows most system updates to be installedon the computer like any other program update without the requirement of anyspecial interaction with the CSI 2600 beyond rebooting it to allow the new version toload.

5.2 Connect the CSI 2600 to the network serverAfter configuring the CSI 2600 with an IP address on the same network as the NetworkServer, connect to the network server through the Ethernet cable.

Procedure

1. If you are using a computer, connect a standard Ethernet cable (included) toconnect the unit's Hub port to the computer.

2. If you need to connect to a Local Area Network to connect to the network server,connect a standard Ethernet cable (included) to the unit's NIC port.

5.3 Configuration overviewThe CSI 2600 is a network-based system. The monitoring unit communicates with a serverthrough an Ethernet connection. In order for the unit and the server to successfullycommunicate, both must have addresses known to each other. The addresses can be


46 MHM-97453, Rev 1

changed, but AMS Machinery Manager must contain the correct IP address for the CSI2600, and the CSI 2600 must contain the IP address of the FTP server from which todownload its firmware.

Complete the following steps (each detailed later in this chapter) to configure thecomputer you use to connect to the unit:

1. Install AMS Machinery Manager on the computer.

2. Configure the computer's IP address.

3. Configure the FTP server to download firmware.

4. Configure boot parameters with a terminal emulator.

5. Add an online server to RBM Network Administration.

NoteIf a computer is purchased from Emerson, this configuration is already complete.

5.4 Install AMS Machinery ManagerInstall AMS Machinery Manager on your computer with the following options checked:

• Network Server

• Online Server

• AMS Machinery Manager Client

Refer to your software user guide for these details.

5.5 Configure the computer's IP addressFollow your operating system's instructions for changing the computer's IP address.

Procedure

1. Make a note of your computer's current settings.

2. Change the IP address assigned to the computer Ethernet port to the addressexpected by a CSI 2600.

Example CSI 2600 system IP addressesTable 5-1:

CSI 2600 Main Processor IP 192.168.0.10

CSI 2600 Transient Processor IP 192.168.0.11

Computer IP 192.168.0.1


MHM-97453, Rev 1 47

5.6 Configure the FTP server to downloadfirmwareFirmware is installed in directory C:\Inetpub\ftproot\bin\ in a folder with a name for the productmodel: 2600 or 2600T.

Each time a CSI 2600 powers up, it scans its network connection looking for the addressthat matches an address stored in internal CSI 2600 memory, and then for firmware at thisdirectory location. If firmware is found, its version is read and compared to a copy offirmware stored in internal CSI 2600 memory. If the firmware is the same revision, then theCSI 2600 boots from its internal copy. If it has a different revision, then the CSI 2600downloads newer firmware, boots using it, and stores a copy of this newer firmware ininternal memory.

Unless otherwise specified, CSI Machinery Health Monitor systems are pre-configured andset up during commissioning.

The FTP service must be configured on a computer on the network so that a CSI MachineryHealth Monitor can obtain firmware updates. If an FTP site is not available, the CSIMachinery Health Monitor boots from the firmware stored in memory. The FTP service is aWindows Feature that is available but not enabled by default on Microsoft Windows. Referto your Microsoft Windows Operating System instructions to enable the FTP Server and setup an FTP site. These instructions are an overview of the steps to configure an FTP serverfor the CSI 6500 on Windows 7 and Windows 2008 R2.

Procedure

1. Go to Control Panel > Programs > Programs and Features and selectTurn Windows Features onor off.

2. Expand Internet Information Services (IIS) and select the following features: FTP Server,FTP Service, and IIS Management Service.

Microsoft Windows configures the services.

3. Launch Internet Information Services Manager.

To find the program, go to Start, type IIS in the search box, and select InternetInformation Services (IIS) Manager.

Internet Information Services (IIS) Manager opens.

4. In the Connections pane, expand the computer node, right-click Sites and select AddFTP Site.

The Add FTP Site dialog appears.

5. Complete the steps in the wizard and configure the settings to match the FTPsettings on the CSI Machinery Health Monitor according to the following example.


48 MHM-97453, Rev 1

CSI Machinery Health Monitor FTP configurationTable 5-2:

Setting Description

Site name The FTP site name to display in IIS Manager. This is for yourreference.

Physical path The path to the bin directory where the firmware will be installed onthe FTP server (do not include the bin directory). C:\Inetpub\ftproot, forexample.

Binding Set Binding to All Unassigned or the IP address or a range of IPaddresses assigned to this computer. Do NOT enable virtual hostnames.

Start FTP siteautomatically

Allow the site to start automatically. Check Start FTP site automatically.

Security Choose Allow SSL and do not select a certificate.

Authentication Choose Anonymous if the CSI Machinery Health Monitor's user (u) andpassword (pw) boot parameters are set to anonymous.

Authorization Choose Anonymous users if the CSI Machinery Health Monitor's user (u)and password (pw) boot parameters are set to anonymous.

Permissions Read

The FTP site name appears in the Connections pane and the site is started.

Postrequisites

Install the firmware on this computer. You can store the firmware for different hardwaremodels on the same FTP server.

CSI Machinery Health Monitor FTP settingsTable 5-3:

Boot parameter Definition Default settings

host inet (h) The IP address of the FTP server 192.168.0.1

user (u) The username for the FTP account anonymous

ftp password (pw) The password for the FTP user anonymous

5.6.1 CSI Machinery Health Monitor firmware updateEmerson Process Management periodically releases updates to firmware. When youupdate your AMS Machinery Manager software, it is a good practice to update thefirmware if a new version is available. Refer to the Readme file (Readme.rtf) on theSoftware Installation DVD for information about the current firmware version. Theseinstructions apply to the following CSI Machinery Health Monitor systems:

• CSI 6500 Machinery Health Monitor

• CSI 2600 Machinery Health Expert

• CSI 4500 Machinery Health Monitor


MHM-97453, Rev 1 49

Install the firmware on the FTP server

Prerequisites

You need the AMS Machinery Manager Software Installation DVD.

Procedure

1. Log on to the computer that hosts the FTP Server for your CSI Machinery HealthMonitor.

2. Insert the AMS Machinery Manager Software Installation DVD.

3. Open the DVD in Windows Explorer and browse to Install/Online Firmware.

4. Double-click setup.exe and continue through the installation.

ImportantOn Windows 7 and Windows Server 2008, right click setup.exe and select Run as administrator.

5. Accept the license agreement.

6. Select the type of installation.

• Select Typical to install the firmware and tools.

• Select Custom to choose to install either the firmware or the tools.

7. Follow instructions presented by the installation program.

The online firmware is installed in C:\Inetpub\ftproot\bin\.

Postrequisites

Cycle the power on each CSI Machinery Health Monitor that uses this FTP server.

Reboot the CSI Machinery Health Monitor

Cycle power on the CSI Machinery Health Monitor and verify the system is in good statusafter it boots.

Procedure

1. Cycle the power on each CSI Machinery Health Monitor that needs to get the newfirmware update from the FTP server.

2. Wait approximately 5 minutes for the system to complete the boot process.

3. Verify the system is powered on and in good status.

Refer to the Installation Manual for your specific hardware model for moreinformation.

Check the firmware version in AMS Machinery Manager1. Log on to AMS Machinery Manager Client with the Administrator user account or a

user that has permission to use online technology.


50 MHM-97453, Rev 1

2. Go to Tools > Setup/Communications > Online Configuration.

The Online Config window appears.

3. Go to File > Online Server > Open.

The Select Online Server Host Computer dialog appears.

4. Choose a server name from the menu and click OK.

The Online Server opens and a tree structure appears in the left pane of the OnlineConfig window.

5. In the tree structure, expand Units folder, and right-click the icon next to the CSIMachinery Health Monitor you want to check and select Properties.

The Unit Properties screen appears in the right pane and displays the State,Firmware Revision, DSP Revision, Total RAM, and Unit Type.

Unit propertiesFigure 5-2:

6. In the Unit Properties pane, verify State is Node(Unit)UP and Firmware Revision matchesthe version you installed.

Contact Product Support for help if the firmware version does NOT match.

5.7 Configure boot parameters with a terminalemulatorDuring normal usage, it is unlikely that you will need to change the initial boot parameters.However, two situations may require changes to boot parameters:

• The CPU or Transient board is being replaced, and the replacement board hasdifferent boot settings.

• The CSI 2600 is added to an existing Ethernet network that is not directly connectedto the online server through a dedicated cable.


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NoteDo not add a CSI 2600 to an existing ethernet network until its IP addresses (CPU board,Transient board) have been verified and changed, if necessary, to be compatible withaddresses already in use on the existing network.

Procedure

1. Turn on the CSI 2600 and start a terminal session.

A screen similar to the following will appear during the boot process:

HyperTerminal System Boot screenFigure 5-3:

2. When the boot process has completed, type bootChange and press Enter to configurethe unit. This command is case-sensitive.

A list of boot parameters appears one line at a time. When configuring the MainProcessor, the screen will look similar to this:

Main Processor boot parametersFigure 5-4:

When configuring a Transient Processor, the screen will look similar to this (note thedifference in the file name value, which includes a "t" for Transient, and the differentboot flags:


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Transient Processor boot parametersFigure 5-5:

NoteOnly change boot flags under the direction of Emerson Product Support.

If allowed to complete without interruption, the boot process should finish with a screensimilar to this:

HyperTerminal Boot Complete screenFigure 5-6:

5.7.1 HyperTerminal navigation after boot completeAfter typing bootChange in a HyperTerminal session, use the following commands tonavigate:

NoteWhen modifying an entry, type the new setting. Do not attempt to backspace over an existing entry.


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HyperTerminal navigation commandsTable 5-4:

Key sequence Description

Enter Accept the value.

. (period) Clear the value when you press the period key followed by Enter.

– (dash) Go back to the previous parameter when you press dash followedby Enter.

Ctrl + B Toggle between Main Processor and Transient Processor.

Ctrl + T Display/hide label that identifies the processor producing output tothe screen.

reboot (case sensitive) Reboot the board with new boot settings.

5.7.2 HyperTerminal navigation after boot interruptYou may interrupt the boot process by immediately pressing Space after the VxWorkscopyright is displayed. If you interrupt the boot process, use the following commands tonavigate the boot configuration console.

The most commonly used commands are ?, @, P, and C.

NoteWhen modifying an entry, type the new setting. Do not attempt to backspace over an existing entry.

CAUTION!

Use only the first four commands (?, @, P, C) in Table 5-5. Contact Emerson Product Supportbefore using the other commands.

Boot interrupt navigation commandsTable 5-5:

Command Description

? Print this list

@ Continue boot (load and go)

P Print boot parameters

C Change boot parameters

g adrs Go to adrs

d adrs[,n] Display memory

z adrs Modify memory

f adrs, nbytes, value Fill memory

t adrs, adrs, nbytes Copy memory

e Print fatal exception

n netif Network interface device address and other important information


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5.7.3 Configure access to a CSI Machinery Health Monitorfrom a computerUse a terminal emulator such as Telnet or HyperTerminal to connect to the CSI MachineryHealth Monitor using a serial cable or an ethernet cable.(1) Configure the settings in Table 5-6 in the terminal emulator's connection settings.

Prerequisites

You need a username and password to log on to a CSI Machinery Health Monitor withTelnet.

Serial connection setupTable 5-6:

Setting Value

serial port COM1

baud rate 9600

data bits 8

stop bit 1

parity none

flow control none

5.7.4 Boot parameters

Boot parametersTable 5-7:

Boot parameter Description

boot device The device name of the system.

• shend0 (CSI 6500 and DCMII systems)• cs (DCMI systems)

processor number 0

host name The username for the FTP user.

file name The path and filename of the firmware installed in the FTP site rootdirectory (C:\inetpub\ftproot, by default).

bin/6500 is the firmware for a CSI 6500.

bin/6500T is the firmware for a CSI 6500T.

inet on ethernet (e) IP Address and Subnet in Hex:

192.168.0.10:ffffff00

inet on backplane (b) Intentionally blank.

host inet (h) The IP address of the FTP server.

Example: 192.168.0.1

(1) Telnet and HyperTerminal are Windows Features that are available but are not enabled by default. You can use other terminal emulatorprograms.


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Boot parameters (continued)Table 5-7:

Boot parameter Description

gateway inet (g) The IP address of the gateway.

user (u) The username for the FTP account.

If the field is set to anonymous the system issues commands with no user.The FTP Server must be set up to allow connections from anonymoususers.

ftp password (pw) The password for the FTP user.

If the field is set to anonymous the system issues commands with no user.The FTP Server must be set up to allow connections from anonymoususers.

flags (f) Boot flags.

Refer to Section 5.7.5 for a description of boot flag values. Add the bootparameters together to specify more than one boot parameter.

target name (tn) (Optional) When you connect to an online system using a terminalsession, the prompt (>) will be preceded by the target name, if set. Ifyou have several terminal sessions open to different online systems,specify a unique target name on each unit to help you identify them.

startup script (s) Intentionally blank. Contact Technical Support for information on usinga startup script.

other (o) (CSI 6500T only) IP Address of WINS server, if configured.

5.7.5 Boot flags

Notes

• This table covers DCMII, DCMIII, and Transient units.

- DCMIII units include the CSI 6500 and CSI 6500T.

- DCMII units include the CSI 4500 and CSI 4500T with blue faceplate (with or withoutdisplay screens).

• Boot flags below are expressed in hexadecimal. To activate more than one boot flag at thesame time, add them together using the Windows Calculator. Select View > Programmer, and fillthe circle for Hex math.

Complete list of boot flagsTable 5-8:

Boot Flag Description

0x0001 Skip SDRAM testing on cold boot (for testing).

0x0002 Load local system symbols (for debug).

0x0004 Don't autoboot (for testing).

0x0008 Quick autoboot (no countdown).

0x0010 Disable input from shell.

0x0020 Disable login security.


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Complete list of boot flags (continued)Table 5-8:

Boot Flag Description

0x0040 Use BOOTP to get boot parameters (network boot only).

0x0080 Use TFTP to get boot image (network boot only).

0x0100 Use Proxy ARP (network boot only).

0x0200 Ignore BOOTROM update image in FLASH (for testing).

0X0400 Change Ethernet speed from 100 Mbps to 10 Mbps (Main Processor only).

0x0400 Redirect the console I/O to COM1 (Transient only).

0x0800 Disable boot file update in FLASH (for development).

0x0800 Boot over a WAN, requiring extended FTP timeouts. This flag applies only if one ofthree flags is set: 0x1000, 0x2000, 0x4000.

0x1000 Attempt network, fallback on FLASH boot (legacy 4500 mode).

0x2000 Boot ALWAYS from network, never fallback on FLASH.

0x4000 Boot ONCE from network. This flag clears itself after one boot.

5.7.6 Subnet masksA subnet mask is normally represented in Windows as a series of four decimal numbers,each of which can have a value from 0 to 255, separated by periods (255.255.248.0).

In the 6560 Processor module, the subnet mask is represented as a series of fourhexadecimal pairs with no separators (that is, 255.255.248.0 is represented as fffff800). Ahexadecimal conversion table can be used to convert the subnet mask numbers fromdecimal to hexadecimal. The calculator in the Windows Accessories folder will alsoperform this conversion when it is set to Programmer Mode.

5.7.7 Specify a subnet maskThe subnet mask on a 6560 Processor module defaults to 255.255.255.0 (ffffff00).

Procedure

1. The subnet mask should be set to match the subnet mask used on the server PC.

If they do not match, network communication failure is possible.

2. On the configuration labeled inet on ethernet, enter the IP address of the unit followedby a colon and then the subnet mask in the hexadecimal format.


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5.8 Add an Online Server to RBM NetworkAdministrationAfter you install AMS Machinery Manager Online Server, add the Online Server in RBMNetwork Administration.

Prerequisites

Install and set up an AMS Machinery Manager Online Server.

Procedure

1. In RBM Network Administration, select Online Server > Add Online Server.

The Add Online Server dialog appears.

2. Click Browse.

3. In the Browse for Computer dialog, select a computer where AMS MachineryManager Online Server has been installed and click OK.

The computer name appears in the Add Online Server dialog.

NoteYou can type the computer name in Online Server Name instead of browsing.

4. Click OK.

The computer name appears in the Online Server pane.

5.8.1 Add a unit's IP address to the Online Server in RBMNetwork AdministrationPrerequisites

Add an online server in RBM Network Administration.

The unit must have an IP address in the same network as that of the online server.

Procedure

1. In RBM Network Administration, select Online Server > Online Server Setup.

The Online Server Setup window appears.

2. Select a server name from the Online Server menu.

The Online Server box displays the AMS Machinery Manager database assigned to theselected Online Server. Active Units lists the CSI Machinery Health Monitorsmonitored by the selected Online Server.

3. If data is being collected, click Stop Data Collection.


58 MHM-97453, Rev 1

Data collection must be stopped to make changes.

The Edit buttons become active.

4. Click Edit beside the Active Units box.

A New Unit field appears.

5. Type in the IP address in New Unit and click Add New.

The unit appears in the Active Units list.


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6 Data collection and analysisTopics covered in this chapter:

• View or edit IP addresses with the unit

• Verify or assign IP addresses to the database

• Database configuration: overview

• Online Watch overview

• Archive management

• Create archives manually

• Disable archive predicates

• Stop transient acquisition

• Remove an archive from the Transient Archive Status tab

• Change databases when moving the unit to a new machine

6.1 View or edit IP addresses with the unitVerify the network addresses of the computer, the unit, and the database.

Procedure

1. Start a terminal session on the CSI Machinery Health Monitor.

If you use a serial connection with PuTTy or HyperTerminal, you do not need ausername and password.

If you use a Telnet connection, log in with the following credentials. Both are case-sensitive:

• username:csi• password: csiSupport

2. At the prompt, type bootChange and press Enter. This command is case-sensitive.

A list of boot parameters appears one line at a time.

3. Press Enter to advance down the list of parameters.

4. Note the IP addresses in the following fields:

The value in inet on ethernet is the IP address of the CSI 2600's Main Processor orTransient Processor.

The value in host inet is the IP address of the computer where the FTP server isinstalled.

5. On your computer, view the IP address of the FTP server by following Windows'instructions for viewing IP addresses. Verify that this address matches the oneshown in host inet.

Data collection and analysis

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6.2 Verify or assign IP addresses to the databaseThe online database must be configured with the IP addresses of assigned monitoringunits.

Procedure

1. Log in to AMS Machinery Manager and click on RBM Network Administration.

2. In the RBMadmin window, double-click the server listed under the Online Serverpanel.

3. In the Online Server Setup window, the Active Units panel lists the IP addresses ofunits available for the online server.

If the system is configured to store data in a database, a database will be displayed inthe Machinery Health Manager Database frame, the two Edit buttons will be inactive,and the Stop Data Collection button will be inactive.

4. If necessary, assign the IP address of a CSI 2600 to Active Units.

a. In the Online Server Setup window, click Stop Data Collection.

b. Beside the Active Units panel, click Edit.c. In the Edit Online Server's Active Unit List window, type the IP address of a new

CSI 2600 in the New Unit field.

d. Click Add New.

The IP address appears in the Active Units panel.

e. Click OK.

The Edit Online Server's Active Unit List window will close.

f. In the Online Server Setup window, click Start Data Collection.

Once a CSI 2600 IP address is listed in RBM Network Administration, that address may beused for any existing or future database built with the online server. This task does notneed to be performed each time a new database is built.

6.3 Database configuration: overviewConfiguring a database is different for a CSI 2600 than for other online monitoringapplications. In most cases, the CSI 2600 is not connected directly to sensors. Rather, it isconnected through coax cable with BNC connectors to a panel of monitoring modules.These modules are connected to field wiring. Therefore, when building a database, it isimportant to have a diagram that shows what sensors are connected to which monitoringmodules. In addition, an analyst who builds a CSI 2600 database needs to know if themonitoring modules perform any signal conditioning on the input signals before passingthem through to their output connectors.


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The CSI 2600 has the capability to provide bias voltage and current (+24 V / 4 mA) foraccelerometers and must be in this configuration if connecting directly to accelerometers.However, if connecting to a module, it is likely that the module powers/biases theaccelerometers and sensor power should not be turned on at each CSI 2600 signalconnection.

6.3.1 Database configuration pre-requisitesHave the following information available before you begin to build a database:

• Sensors connected to each CSI 2600 signal channel; sensitivity, offset (eddy currentsensors, thrust probes), signal range.

• Source of sensor power for accelerometers.

• Definition of the transient event (speed drops below 3585 RPM, input relay fromexternal control system changes state, etc.)

• Sensors for which transient measurements are desired.

• IP address of a CSI 2600.

• Bearing clearances (radial eddy current sensors).

• Resting DC voltage measurements for radially mounted eddy current sensors.

6.3.2 Collection predicatesPredicates are conditions that have a value of True or False, and are used to guidemeasurement operations.

A Collection Predicate tells the system when to perform a routine data collection basedupon the definition created in the database. Inputs into this type of predicate include:

• speed

• Gross Scan AC amplitude

• Gross Scan DC amplitude

• discreet input signal

• another predicate

An example of a Collection Predicate for a CSI 2600 transient operation would be "Speedbelow 3585 RPM". This predicate will have a value of False if speed is above 3585 RPM. Itwould have a value of True if speed is below 3585 RPM.

6.3.3 Configure a collection predicateUse Online Configuration to create a collection predicate.

Procedure

1. In the tree structure in the left panel, expand Units, expand the CSI 2600 that willcollect data, right-click the Predicates folder, and select Add Collection Predicate.

2. Enter a name for the predicate. Do not include spaces.


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3. Click the Tach drop-down menu and select the tachometer to be used foracquisition.

This will be a tachometer connected to CSI 2600 tach location 1, 2, 3, or 4.

The Tach Clause dialog opens.

4. Click the Comparison drop-down menu and select an equation for the predicate.

5. Enter an RPM value in the Speed1 field.

6. Click OK.

7. Click Apply to finish.

6.3.4 Configure a database for transient operationThe CSI 2600 system may be used to simultaneously monitor machinery under normaloperating conditions and to create a large archive of information for those signalsdesignated (while building the database) as transient. All sensor connections to the CSI2600 are configured for predictive operation. Some (or all) of these are also designated astransient and are configured for transient operation.

Procedure

1. Create collection predicate for transient auto-archive operation.

When you create an auto-archive definition, this collection predicate will cause theCSI 2600 to automatically transfer an archive of transient measurements to theonline server, where they can be viewed by an analyst. Archives stored on thetransient hard drive will eventually be written over by new measurements.

2. Configure the Measurement Points to associate tach channels with vibrationchannels.

a. In Online Configuration, right-click Areas, select Add Area.

b. Enter an Abbreviation and Description, and click Apply.

c. Right-click the newly created Area and select Add Equipment.d. Enter an Abbreviation and Description, and click Apply.

e. Right-click the newly created Equipment and select Add Component.f. Enter an Abbreviation and Description, and click Apply.

g. Right-click the newly created Component and select Add Measurement Pt.h. Enter an Abbreviation and Description, and click Apply.

i. With Component Properties still open, click the Monitoring Unit tab.


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Online Configuration—Component PropertiesFigure 6-1:

j. In the CSI Online Monitoring Unit field, click Attach.

k. Select the unit and click Okay.

l. In the Component Properties field, click Apply.

3. Commission transient channels.

Transient channels may be commissioned all at once, unlike prediction channels. Ananalyst may designate some or all of the already commissioned predictive channelsfor transient operation. Some signals, such as case expansion may not includevaluable transient information. In this case, they do not need to be commissioned astransient—only as predictive signals.

a. In the Online Configuration tree structure, right-click on the unit and selectCommission Transient Channels.

The Commission Transient Channels dialog appears, showing signals alreadycommissioned for predictive operation.

b. Select the desired tach channel, and click the check box for each signal input youwant to associate with the tach channel.

c. Click the Acquire button.

Measurements for the entire set of signals are shown.

d. Click Commission to commission the channels for transient operation.


MHM-97453, Rev 1 65

Data collection starts when you save the configuration to the O_server, whichalso downloads it to the unit.

4. Create an Auto-Archive definition.

This tells the CSI 2600 when to automatically send an archive of measurements tothe online server.

a. Right-click the Transient Tachometer and select Transient Auto-Archive Properties.

The Auto-Archive Properties dialog appears.

b. Set the Pre-trigger time (in minutes) and Post-trigger time (in minutes).

Pre-trigger time indicates how long the auto-archive will take measurementsbefore the collection predicate changes to TRUE. Post-trigger time indicates howlong the auto-archive will take measurements after the collection predicatechanges to TRUE.

After all measurements have been collected, the archive will be sent from the CSI2600 to the online server.

6.3.5 Review and save a transient databaseAfter creating a database, create a report to review your database configuration. Thereport includes:

• firmware revision used by the unit

• calibration information for the unit

• predicates and their definitions

• signal connections, transient or predictive

• tachometer definitions

• relay definitions

Procedure

1. In the Online Configuration tree structure, right-click on the unit and select Report.2. Select File > Online Server > Save.

The database configuration is downloaded to the unit.

6.4 Online Watch overviewAMS Machinery Manager Online Watch monitors system status and views the latestmeasurements.

To open Online Watch, log in to AMS Machinery Manager, click the Tools tab, and in the leftpanel, click Analysis.

Online Watch can perform four specific transient operations:


66 MHM-97453, Rev 1

• Create archives manually.

• Disable archive predicates.

• Stop transient streaming to the CSI 2600.

• Remove archives from the Transient Archive Status tab.

Transient system status includes:

• Streaming/not streaming to HDD

• Time of oldest recorded information

• Progress of archive creation

The Online Watch screen displays CSI 2600 status, and the status of any archives. Thisdisplay has two tabs, Transient Status and Transient Archive Status.

Transient archives are stored under the server folder …\CustData. Two items will be createdin this folder. One is the actual CSI 2600 database file, with an .rbm extension. The other is asub-folder with the same name as the CSI 2600 database. Inside this sub-folder is acollection of other folders, including one named archives. Transient archives are storedunder this archives folder, with a separate folder for each archive.

6.4.1 Online Watch—Transient Status tab

Online Watch—Transient StatusFigure 6-2:


MHM-97453, Rev 1 67

Transient Status tab fieldsTable 6-1:

Field Message Description

Status Node(Unit)Up Unit is ready to monitor using the database definition.

AcknowledgedUnit is reorganizing internal software and schedules to conform to thedatabase definition.

CurrentAcquisitionState

Transient Acquisition hasstarted

Transient measurement is proceeding normally.

Transient Acquisition hasstopped

Transient measurement was manually stopped.

Unknown Temporary message after a database is downloaded.

ActiveStreamingLocation(1)

Primary Transient system is recording to the primary drive, as specified in OnlineConfiguration > Unit Properties.

Failover Transient system has detected a problem with the primary drive and isrecording to a Failover drive, as specified in Online Configuration > UnitProperties.

TransientDrive Details

Oldest Data Date and time of the oldest measurements currently stored in the unit.Update this field by clicking Refresh.

Newest Data Date and time of the newest measurements currently stored in the unit.Update this field by clicking Refresh.

StorageLocationConfiguration

Primary Path displays which drive—Internal, External, No Path—has been specifiedas the primary streaming location. Size displays how much memory isavailable.

Failover Path displays which drive—Internal, External, No Path—has been specifiedas the secondary streaming location. Size displays how much memory isavailable.

Auto-ArchiveStatus

Tach # Tachometer input associated with a group of transient vibrationchannels.

Speed Current speed measured by the Tach input.

Predicate Name of the predicate used for triggering the auto-archive .

Last Report Date and time of the most recent archive.

State True means the parameters of the auto-archive predicate are being metand data is being recorded to the drive. An analyst can select theTransient Archive Status tab to monitor the progress of archive creation.

False means the parameters of the auto-archive predicate are not beingmet and data is not being recorded.

Disabled means the automatic archive predicate has been disabled.

(1) The Active Streaming Location is where transient data is recorded during normal/constant CSI 2600 operation. Measurements fromthis drive are extracted when an archive is created, and sent as a folder (archive to the online server).

6.4.2 Online Watch—Transient Archive Status tabThe Transient Archive Status tab shows archives that are currently being created.


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Online Watch—Transient Archive StatusFigure 6-3:

Transient Archive Status fieldsTable 6-2:

Field Message Description

Component (variable) Displays the machine component associated with the transient archivegroup.

Archive Name (variable) Displays the name of the archive that was specified in OnlineConfiguration.

Range 1500_2985 indicates that the collection predicate is TRUE forspeeds between 1500 and 2985 RPM.

The number in _0__ is reserved to ensure the filename is always unique.

05-30-2007 indicates the date the archive was created, in mm-dd-yyyformat.

10.17.07 indicates the time the archive was created, in hh.mm.ss format.

Archive Status Pending The system is waiting for post-trigger data to be collected, beforesending that data to the database.

Archiving The system is sending a complete set of measurements to the onlineserver.

Complete All measurements have been sent to the online server.

Archive Type Predicate + parameters The archive was initiated by a predicate.

Manual The archive was initiated on-demand by a user.

PercentComplete

00.00%–100.00% Displays progress while the system sends measurements to the onlineserver.

6.5 Archive managementArchives are stored in folders in C:\RBMnet\RBMsuite\CustData\.

Computers have a finite amount of video display memory that may limit the amount ofgraphic data viewed in an archive. To achieve efficient CSI 2600 system operation, ananalyst should regularly review extracted archives and keep only those of interest or onlythe portions of interest in each archive. An analyst can extract smaller archives from largeones using the program Vibration Analysis. To extract and view large amounts ofinformation from the CSI 2600, an analyst should sequentially extract individual archives of1 - 2 hours of measurements.


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6.6 Create archives manuallyThere are three major differences between manually created archives and automaticallycreated archives:

• Manual archives only include information already in the CSI 2600. Automatically-generated archives can include information which is received after the transientcollection predicate = TRUE.

• Manual archives do not automatically have a date-time stamp appended to them.Ensure that unique names are assigned.

• Manual archives may have more than one hour of measurements in them.Automatically generated archives have a maximum of 60 minutes ofmeasurements.

Procedure

1. In Online Watch, select a component that has transient signals.

2. Right-click and select Start Transient Archive.

3. Define the manual archive characteristics.

Postrequisites

Observe the progress of manual archives in the Transient Archive Status tab.

6.7 Disable archive predicatesAn analyst can disable the creation of automatic archives during startup or when themachine is being cycled and multiple archives are not desired.

Procedure

1. In the Transient Status tab, right-click on the archive predicate and select DisableArchive Predicate.

A caution window appears.

2. Click Okay to confirm disabling.

The predicate State on the Transient Status tab reads Disabled.

To re-enable the archive, right-click on the archive predicate and select Enable ArchivePredicate.

Example: Archive creation

When an archive predicate changes from DISABLED to TRUE, no archive is created.Consider the following sequence:

1. Archive predicate is false.

2. Archive predicate is disabled prior to machinery start-up.


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3. Machine starts up and increases to a speed of 1800 RPM.

4. Archive predicate is re-enabled.

5. Archive predicate immediately changes to value of TRUE.

6. No archive is created.

7. Machine speed continues to rise and reaches a speed of 3000 RPM.

8. Archive predicate changes to value of FALSE.

9. Machine trips and speed drops below 2985 RPM.

10. Archive predicate changes to value of TRUE.

11. Archive is automatically created and sent to online server.

Disabling or re-enabling archive predicates only determine whether or not the CSI 2600will send an archive to the online server. This does not stop the CSI 2600 from recordingmeasurements. In the above sequence, an analyst could extract a manual archive startingat the time when the archive predicate was initially false and ending at the time that themachine was at 3000 RPM.

6.8 Stop transient acquisitionAn analyst can command the CSI 2600 to stop recording transient data.

Procedure

1. In the Online Watch tree structure, right-click on the CSI 2600 and select StopTransient Acquisition.

A caution window appears.

2. Click Okay to confirm.

In the Transient Status tab, Current Acquisition State displays the message TransientAcquisition has stopped, and the CSI 2600 is no longer streaming data to the designated drive.

6.9 Remove an archive from the Transient ArchiveStatus tabIn the Transient Archive Status tab, right-click on the archive and select AcknowledgeTransient Archive.

NoteRemoving archives does not delete archives from the online server; it only removes them from thelist in the Transient Archive Status tab.


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6.10 Change databases when moving the unit to anew machineBecause the CSI 2600 is a portable system, analysts must ensure that measurements fromone machine are not stored in a database or archive folder for a different one.

CAUTION!

Ensure that the following sequence is observed whenever moving the CSI 2600 from onemonitoring rack or machine to another. Data from one machine could be stored in thedatabase of another machine if this sequence is performed incorrectly.

CAUTION!

Changing databases will reinitialize the Transient HDD, which eliminates all stored data.Extract any data before changing databases.

Prerequisites

Before disconnecting from the first machine, log in to AMS Machinery Manager.

From the Tools tab, click Setup/Communication and open RBM Network Administration.

Procedure

1. In the bottom center panel labeled Online Servers, double-click the server.

The Online Server Setup dialog opens.

2. Click Stop Data Collection.

3. Disconnect the unit from the first machine.

4. Connect the unit to the second machine.

5. In Online Server Setup, click the Edit button next to Machinery Health ManagerDatabase—not next to Active Units.

6. Select the second machine's database when prompted.

7. In Online Server Setup, click Start Data Collection.

The system will now store any measurements or archives in the second database.


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Appendix ASpecifications

Topics covered in this appendix:

• CSI 2600 product specifications

• Module specifications

A.1 CSI 2600 product specificationsThe CSI 2600 Machinery Health Expert comes in a case with a retractable handle and twowheels for roll around transport.

Physical dimensions—caseTable A-1:

Height 13.75 in.

Width 19.5 in.

Depth 24.5 in.

Weight (with case and unit) 53 lb.

Physical dimensions—unitTable A-2:

Height 20.5 in.

Width 8.25 in.

Depth 16 in.

Weight (unit alone) 30 lb.

Operational conditionsTable A-3:

Relative humidity Temperature range

0–95% R.H. non-condensing -17–55°C

0–50% R.H. non-condensing -17–65°C

Specifications

MHM-97453, Rev 1 73

A.2 Module specifications

A.2.1 6560 Processor module

6560 Processor module specifications at 25°C

6560 Processor module specifications at 25°CTable A-4:

Memory Capacity 32 MB SDRAM, 32 MB Flash

Network Communication 10/100Base-T Ethernet dual RJ45 jacks wired for NIC and HUB, with two additionaljacks on backplane

Local Communication RS232 (up to 38.4 Kbs)

Onboard Test Generator All sensor channels, tachometer channels, AC, DC amplitude, phase (0 V - 3 V pk,0.25 Hz - 50 kHz sine +/- 7.2 VDC, GND +/- 1 mV)

Rack Health Relay SPDT 24

Sensor Channel Scan RMS + DC, rate equivalent to16 ch per 500 ms

Overall Vibration Units RMS, RMS or peak-to-peak with Transient Option

DC Scan Simultaneously scanned with overall vibration scan (includes DC Gap,temperature, and accelerometer bias)

Gross Scan and DC Accuracy 1% at input channel range full scale amplitude @ 1 kHz

Gross Scan ADC Resolution 16 bit

Data Acquisition Event Basis Relay input, RPM, DC, AC or software controlled

Data Collection Event-based adaptive

Data Collection Interval Event-based and/or time-based

Data Storage Interval Exception-based and/or time-based

Spectral ADC Resolution 24 bit, 2 channel simultaneous

Dynamic Range 100 dB, all frequency ranges

Spectral Resolution 100 to 6400 lines

Analysis Bandwidth 10 Hz to 40 kHz, discrete steps

Spectral Scan Rate Depends on analysis configuration (1 second per two channels @ 400 lines, 400 Hz1 avg)

Spectral Amplitude Accuracy 5% 0.2 Hz - 0.5 Hz 2% 0.5 Hz - 25 kHz 4% 25 kHz - 40 kHz

Frequency Accuracy 0.01%, crystal based

Total Harmonic Distortion <-90 dB, all ranges

1X Synchronous Peak Accuracy 3% 0.5 Hz - 3 Hz 2% 3 Hz - 1 kHz 5% 1 kHz - 5 kHz

1X Synchronous Phase Accuracy 4 0 1 Hz - 1 kHz (not calibrated below 1 Hz) 5 0 >1 kHz

Analysis and Trend Types Configurable, with user-defined parameter names, multiple analysis types permachine and per sensor. (Total Energy, Energy in a range. Non-sync energy in arange, Sync energy in a range, Sync peak, Sync phase, True peak, HFD, Waveformpeak-to-peak, RPM, Gap, Orbit)

Specifications

74 MHM-97453, Rev 1

6560 Processor module specifications at 25°C (continued)Table A-4:

Averaging Types Normal, PeakVue, Order Tracking, Synchronous Time Averaging

Units Types English, Metric, HZ, CPM, Order

Scaling Types Linear, Log, dB

Windows Types Hanning, Uniform

Processor module LEDs

The 6560 Processor module has seven two-color LEDs. From top to bottom these are:Input Power, CPU Status, Transient Status, System Status, Server Connect, ModbusConnect, and Hard Drive Active.

6560 Processor module LEDsFigure A-1:

Specifications

MHM-97453, Rev 1 75

Input Power LED

The Input Power LED indicates the status of the power converters that distribute variousvoltages within the 6560 Processor module. A steady green color indicates that all powerconverters are within the proper voltage ranges, while a steady or blinking red conditionindicates a power fault somewhere inside the 6560 Processor module.

CPU Status LED

The CPU Status LED indicates the status of the Main Processor board. The four statusconditions are listed in Table A-5 along with their assigned priorities.

More than one status condition may be active at one time. When this happens, the LED willindicate the active status condition with the highest priority. For example, if the module isboth Uncalibrated (Priority 3) and is also currently In POST (Priority 1), the LED would indicateIn POST.

CPU status conditionsTable A-5:

LED Color Status Priority Comments

Blinking Green In POST 1 Typically only seen during system startup. Indicatesthat POST (Power On Self Test) is being performed,which involves Processor board resources.

Solid Red Failure 2 Power supply POST failure, or other hardwarefailure on processor board.

Alternating Red/Green

Uncalibrated 3 The onboard Test Function generator isuncalibrated.

Solid Green OK 4 Normal operation.

Transient Status LED

The Transient Status LED indicates the status of the Transient Daughterboard. The LED isalways off when a Transient board is not installed in the system. The four status conditionsare listed in Table A-6 with their assigned priorities.

More than one status condition may be active at one time. When this happens, the LED willindicate the active status condition with the highest priority.

Transient Daughterboard status conditionsTable A-6:





Uncalibrated 3 One or more Transient channels are uncalibrated.

Specifications

76 MHM-97453, Rev 1

Transient Daughterboard status conditions (continued)Table A-6:



System Status LED

The System Status LED indicates the status of the overall system. It indicates the activestatus condition with the highest priority of all boards in the system. For example, if theTest Function generator on the Main Processor board is uncalibrated and the first MSIGmodule has a power fault, the LED will show a solid red color to indicate the MSIG modulepower fault, which is a “Failure” state.

When all the firmware components are operating as expected, this LED overlays a“heartbeat” pulse pattern on top of the system status. The heartbeat pattern occurs in afour-count cycle. The LED is pulsed off briefly during each of the first and second counts,and then left on during the 3rd and 4th counts. In practice, it gives the appearance of ahuman heartbeat. If the heartbeat stops, it indicates a firmware fault has occurred. Manytimes the system is capable of recovering from a missed heartbeat. However, if the systemcannot recover quickly, it will automatically reboot itself to clear the fault and will thenresume monitoring.

Server Connect LED

The Server Connect LED indicates when Machinery Health Manager software or the DHMdiagnostic software are connected.

• A green color indicates that at least one Machinery Health Manager software clientis connected or that the DHM software is connected in the client mode.

• A red color indicates the DHM software is connected in the Single User mode. In thisstate, no other clients can connect.

• If the LED is off, it indicates that neither of these types of software clients areconnected.

There is no indication of client data transfer, only the presence of at least one establishedconnection.

Modbus Connect LED

The Modbus Connect LED indicates when a Modbus client, Web Browser, or Transient Liveclient are connected.

• A green color indicates that at least one of these types of clients has established aconnection.

• If the LED is off, it indicates that none of these types of clients is connected.

The red color is not used with this LED.

There is no indication of client data transfer, only the presence of at least one establishedconnection.

Specifications

MHM-97453, Rev 1 77

Hard Drive Active LED

The Hard Drive Active LED indicates when the onboard Transient hard drive is beingaccessed with read/write activity.

The green LED blinks on each time a read or write activity accesses the Transient harddrive. The more time the LED is green, the more hard drive activity.

This LED is always off if there is no Transient board installed in the system.

Specifications

78 MHM-97453, Rev 1

A.2.2 6510 Signal Input module

Signal Input module specifications at 25°C

Signal Input module specifications at 25°CTable A-7:

Sensor Input Types Dynamic displacement probe, Accelerometer, Velocity probe, AC input - customdefinable (for example, Flux, Dynamic pressure sensor, Dynamic basis weight input, etc.),DC input - custom definable (for example, Temperature or other process input), 4-20 mASignal (with external shunt resistor).

Number of Sensor Inputs 16 inputs per module (12 sensor, 2 tach, 2 I/O, 2 modules per rack)

Analysis Bandwidth 0.2 Hz to 40 kHz (0.2 Hz to 2 kHz for Transient Analysis)

AC Coupling CornerFrequency

0.5 Hz

RMS Conversion Accuracy 1% at full scale amplitude 30 Hz - 40 kHz 2.5% at full scale amplitude 20 Hz 5% at full scaleamplitude 10 Hz (uncalibrated below 10 Hz)

DC Accuracy 1% at full scale amplitude

Analog Integration 1 per channel (acceleration to velocity or velocity to displacement)

Analog Integrator Accuracy 2% (frequency and amplitude)

AC Input Range Software configurable: + 5 V pk, + 10 V pk

DC Input Range + 22 VDC

Maximum AC + DC InputRange

+ 22 V

Powered Sensor Types ICP Accelerometer and velocity probes by each sensor channel, and displacement probesby fused -24 VDC power supply on each channel

Sensor Power 4 mA (nominal) constant current, with 22 V compliance per current

Powered Channel InputImpedance

500 kOhm (single ended)

Non-Powered Channel InputImpedance

1 MOhm (differential)

Non-Powered Sensor Type Displacement, AC or DC process

RMS to DC Converter 1 per channel, 1 Hz to 40 kHz

Number of TachometerChannels

2 inputs per module, 4 total per rack

Tachometer FrequencyRange

0.1 Hz to 2 kHz (6 RPM to 120,000 RPM)

Tachometer FrequencyAccuracy

0.1%

Tachometer Resolution 0.002 Hz @ 60 Hz (0.1 RPM)

Tachometer Types Eddy current displacement probe, TTL, passive magnetic

Tachometer Amp. Range Input and trigger pulse range + 0.5 V pk to + 22 V pk

Pulse Characteristics 1 pulse per revolution, 500 uS minimum pulse width, tach divider on module

Specifications

MHM-97453, Rev 1 79

Signal Input module specifications at 25°C (continued)Table A-7:

Modes Volt compare, automatic adaptive, divide by N (N=1-1024)

Input Impedance 1 MOhm (differential)

Number of Digital I/OChannels

2 per module (configurable as input or output), 4 total per rack

Relay Type SPST 24 VDC @ 0.5 ADC dry contact

Digital Input Current Max. 10 mA @ 24 VDC

Digital Input High Voltage 5 VDC - 24 VDC

Digital Input Low Voltage <3 VDC

Signal Input module LEDs

Every 6510 Signal Input module has two, two-color LEDs. The top LED indicates the powerconverter status and the bottom LED indicates overall module status.

Specifications

80 MHM-97453, Rev 1

6510 Signal Input module LEDsFigure A-2:

Power LED

The Power LED indicates the status of the MSIG module power converters.

A steady green color indicates that all voltage levels are OK, while a steady or blinking redcondition indicates a power fault somewhere within the module.

Status LED

The Status LED indicates the overall status of the module. The four status conditions arelisted in Table A-8 along with their assigned priorities.

More than one status condition may be active at a time. When this happens, the LED willindicate the active status condition with the highest priority.

Specifications

MHM-97453, Rev 1 81

If the Status LED is off, the Signal Input module is being ignored by the 6560 Processormodule. This is a special case which should not be encountered in practice. Modules areonly ignored if the addition of the module would exceed the maximum channel countlimits that the 6560 Processor module can support (24 analog, 4 Tach, 4 I/O). Channels arecounted starting in the left-most.

Signal Input Module status conditionsTable A-8:





Uncalibrated 3 One or more channels are uncalibrated.


Transient Filter Board specifications

Transient Filter Board specificationsTable A-9:

Number of channels 12

Filter type 8th order elliptic low pass

Filter passband frequency DC to 2 kHz

Attenuation 80 dB

Passband ripple <1 dB

Stop band frequency 3.12 kHz

Specifications

82 MHM-97453, Rev 1

Appendix BSystem calibration

The CSI 2600 uses internal calibration tables to compensate for slight measurementvariations that can occur across the temperature, voltage ranges, and variations inindividual electronic components used by processing circuitry. These calibration tables arestored in each CSI 2600 when it is assembled and verified at the factory. The units applycalibration corrections automatically during signal measurement and processing.

The CSI 2600 system calibration consists of two steps:

1. Calibrate the on-board signal generator.

2. Calibrate the system.

The Processor Module signal generator should be recalibrated at least once a year.

The CSI 2600 should be recalibrated at least once a year, or when the processor or a signalinput module has been replaced. To recalibrate an installed system, contact a localEmerson Online Product Support office to schedule recalibration during an equipmentoutage. Calibrations can be completed in less than an hour, but units cannot monitorrotating equipment during that time.

B.1 The CSI 6560 Processor moduleFour circuits are calibrated:

• Test Signal Generator (TSG)

• Gross Scan (GS)

• Digital Signal Processor (DSP)

• Transient

The TSG circuit is a key element. This circuit provides an extremely precise output signal,which is used as an input during GS, DSP/Tachometer, and Transient calibrations(Tachometer channels are calibrated during DSP calibration). During calibrations, the TSGoutput is routed internally in the 6560 Processor Module, to processing electronics (GS,DSP, Tach, Transient), and individual calibration tables for each processing circuit arecreated and stored in 6560 Processor Module memory. These tables are stored in non-volatile memory, which means that the tables are not erased if the 6560 Processor Moduleis powered down.

The TSG circuit provides an output signal, which is used to create all of the othercalibration tables. The TSG circuit has its own calibration table, stored in the CPU board. If aCPU board is replaced, then the other calibrations need to be rerun for that 6560 ProcessorModule, since their original calibration tables used the TSG signal from the original CPUboard.

System calibration

MHM-97453, Rev 1 83

Calibration tables may be copied from each 6560 Processor Module onto an online server,and those can be downloaded into the same 6560 Processor Module. Emerson OnlineProduct Support personnel and Online Systems Engineers can assist customers with thistype of operation.

Calibration circuit inputs and outputs are shown in Section B.1.1

B.1.1 Calibration circuits input and output

Calibration circuits input and outputTable B-1:

Calibration circuit Input Output

TSG (Test Signal Generator) (external) signal TSG table (internal) TSG signal

GS (Gross Scan) TSG signal GS table

DSP (Digital Signal Processor) TSG signal DSP table

Transient TSG signal Transient table

B.1.2 Test Signal Generator (TSG) calibrationAll CPU boards provided by Emerson are shipped with a calibrated TSG circuit. If the CPUboard is purchased as part of a system, the entire system is calibrated using the CPU boardTSG circuit.

The TSG circuit is the only element that requires an external piece of test equipment andspecial connection cables. TSG calibration requires:

• Digital Multi Meter (such as the HP 34401A)

• computer configured as online server

• special calibration utility program (DHM)

• cable that connects the computer to the 6560 Processor module Ethernet port

• cable that connects the computer to the Digital Multi Meter

• cable that connects the Digital Multi Meter to the test port on the unit

TSG calibration is unique in that it requires a separate test instrument, unique cables, and acomputer that is configured as an online server. It is recommended that qualified EmersonOnline Systems Engineers perform TSG calibration or recalibration.

B.1.3 Gross Scan (GS) calibrationGS calibration:

• uses a 6560 Processor module's TSG output signal.

• does not require that any wire harnesses be disconnected.

• is completed in about 10 minutes.

• does not require any special cables or test equipment.

System calibration

84 MHM-97453, Rev 1

• uses a special calibration utility program (DHM).

GS recalibration should be performed:

• annually.

• whenever a 6510 Signal Input module is replaced.

• whenever a 6560 Processor module is replaced.

• if the calibration table has a status of "Unknown".

Product Support personnel can guide a plant engineer or technician through GS calibrationover the phone.

B.1.4 Digital Signal Processor (DSP) calibrationDigital Signal Processor (DSP) calibration:

• uses a CPU board's TSG output signal.


• is completed in about 30-40 minutes.



DSP recalibration should be performed:

• annually.


• whenever a 6560 Processor module is replaced.

• if the calibration table has a status of “Unknown”.

Product Support personnel can guide a plant engineer or technician through DSPcalibration over the phone.

B.1.5 Transient calibrationThe Transient unit includes two processing boards—a Main Processor board and aTransient board. Both boards include separate Digital Signal Processors. The DSP on theTransient board uses an internal calibration table, in much the same way that the MainProcessor DSP circuit does. However, it is calibrated separately, and not as part of a DSPcalibration for a Main Processor.

Transient calibration:

• uses a Processor module's TSG output signal.


• is completed in about 30-40 minutes.



System calibration

MHM-97453, Rev 1 85

Transient calibration should be performed:

• annually.


• whenever a Transient board is replaced.

• whenever Main Processor board is replaced.

• if the calibration table has a status of "Unknown".

Product Support personnel can guide a plant engineer or technician through Transientcalibration over the phone.

System calibration

86 MHM-97453, Rev 1

Appendix CData types


• Gross Scan analysis

• Spectral analysis

• Time Waveform analysis

• Non-Vibration unit analysis types

• Set DC offset

C.1 Gross Scan analysisIncludes Overall RMS Level, Sensor DC Bias, Gap, DC, or AC Process signals.

NoteSome DC Process Inputs could provide pk, pk-pk, or other Measurement Units.

Gross Scan parameters

All Gross Scan inputs must be DC in nature. Any Gross Scan input of a dynamic nature mustbe fed through the RMS/DC converter path. It is not technically valid to convert RMS valuesfrom an RMS/DC converter to pk or pk-pk Measurement Units unless the input is sinusoidalin nature. However, the CSI 2600 allows this. RMS values are multiplied by 1.414 or 2.828to convert from RMS to pk and pk-pk, respectively.

C.1.1 Gross Scan units conversion

Gross Scan units conversionTable C-1:

InputType Input Unit HW Int. RMS/DC Meas. Unit Disp. Unit

DC V / E.U. no no DC E.U.

AC V / E.U. no yes RMS E.U.

ACCEL V / 32.2 ft/s

V / 32.2 ft/s

V / 9.81 m/s

V / 9.81 m/s

no

yes

no

yes

yes

yes

yes

yes

RMS

RMS

RMS

RMS

g

in./s

g

mm/s

Data types

MHM-97453, Rev 1 87

Gross Scan units conversion (continued)Table C-1:

InputType Input Unit HW Int. RMS/DC Meas. Unit Disp. Unit

VEL V / i/s

V / i/s

V / mm/s

V / mm/s

no

yes

no

yes

yes

yes

yes

yes

RMS

RMS

RMS

RMS

i/s

mil

mm/s

micron

DISP V / mil

V / micron

no

no

yes

yes

RMS

RMS

mil

micron

C.2 Spectral analysisSpectral analysis includes:

• Total Energy

• Energy within a Frequency Range

• Synchronous Energy within a Frequency Range

• Non-Synchronous Energy within a Frequency Range

• HFD

• Relative Synchronous Harmonics

• Average

• Synchronous Peak

NoteTotal Energy, Energy within a Frequency Range, Synchronous Energy within a Frequency Range, Non-Synchronous Energy within a Frequency Range, HFD, Relative Synchronous Harmonics, Average,Synchronous Peak.RMS, pk, pk-pk Measurement Units are valid and can be freely converted.

Spectral Scan parameters

All Spectral Scan parameters must be AC in nature. It is possible to convert some analysistype results between Measurement Unit types and Display Unit types.

C.2.1 Spectral units conversion

Spectral units conversionTable C-2:

InputType Input Unit HW Int. SW Int. SW Diff. Disp. Unit

AC V / E.U. no no no E.U.

Data types

88 MHM-97453, Rev 1

Spectral units conversion (continued)Table C-2:

InputType Input Unit HW Int. SW Int. SW Diff. Disp. Unit

ACCEL V / 32.2 ft/s

V / 32.2 ft/s

V / 32.2 ft/s

V / 32.2 ft/s

V / 32.2 ft/s

V / 32.2 ft/s

V / 9.81 m/s

V / 9.81 m/s

V / 9.81 m/s

V / 9.81 m/s

V / 9.81 m/s

V / 9.81 m/s

no

no

no

yes

yes

yes

no

no

no

yes

yes

yes

no

single

double

no

single

no

no

single

double

no

single

no

no

no

no

no

no

single

no

no

no

no

no

single

g

in./s

mil

i/s

mil

g

g

mm/s

micron

mm/s

micron

g

VEL V / i/s

V / i/s

V / i/s

V / i/s

V / i/s

V / mm/s

V / mm/s

V / mm/s

V / mm/s

V / mm/s

no

no

yes

no

yes

no

no

yes

no

yes

yes

yes

yes

yes

no

single

no

no

no

no

no

no

single

single

no

no

no

single

single

i/s

mil

mil

g

i/s

mm/s

micron

micron

g

mm/s

DISP V / mil

V / mil

V / mil

V / micron

V / micron

V / micron

no

no

no

no

no

no

no

no

no

no

no

no

no

single

double

no

single

double

mil

i/s

g

micron

mm/s

g

C.3 Time Waveform analysisTime Waveform analysis includes:

• Variance

• True Peak

• Waveform pk-pk

Data types

MHM-97453, Rev 1 89

NoteMeasurement Unit type is specific to Analysis type. No Software Integration Differentiation can beperformed.

C.3.1 Time Waveform units conversion

Time Waveform units conversionTable C-3:

Input Type Input Unit HW Int. Disp. Unit

AC V / E.U. no E.U.

ACCEL V / 32.2 ft/s

V / 32.2 ft/s

V / 9.81 m/s

V / 9.81 m/s

no

yes

no

yes

g

in./s

g

mm/s

VEL V / i/s

V / i/s

V / mm/s

V / mm/s

no

yes

no

yes

i/s

mil

mm/s

micron

DISP V / mil

V / micron

no

no

mil

micron

C.4 Non-Vibration unit analysis typesNon-Vibration unit analysis includes:

• Peak to Average Ratio

• Average to Minimum Ratio

• Kurtosis

• Skewness

• Synchronous Phase

These analysis types produce non-unit ratios or specific unit types such as degrees ofphase. Measurement Unit Type will not apply to these parameters.

C.5 Set DC offsetFor thrust probes, the input channel is defined as a DC Process input. Set the DC offset sothat the thrust reading may be zeroed.

Data types

90 MHM-97453, Rev 1

Procedure

1. Use a DC voltmeter (or the DHM program) to measure the DC voltage as seendirectly on the inputs.

2. In Online Configuration, right-click on a unit and select Configure Unit.3. Right-click a channel icon and select Define.

4. Set the Signal Type to Process.

5. Select Properties and select the Sensor button.

6. Highlight New and select OK to define a new sensor.

7. Enter the voltage value into Offset Field.

Data types

MHM-97453, Rev 1 91

Data types

92 MHM-97453, Rev 1

Appendix DInternal wiring of the CSI 2600


• Rear termination panel

• Internal wiring diagram for the CSI 2600

• Terminal descriptors

• Rear terminal power connections

• CSI 2600 DIP switch settings

D.1 Rear termination panelThe rear termination panel plugs directly onto the backplane. This termination panel hasconnectors for sensor inputs, tachometer inputs, and discrete input/output relays into the12-2-2 modules. All these connections are available through BNC connectors on the rear ofthe CSI 2600.

A6500-M-RTRMFigure D-1:

A6500-M-RTRMTable D-1:

Termination panel

A

B

Sensor inputs: MSIG1 (Ch1–12)

Sensor inputs: MSIG2 (Ch13–24)

C

D

Tach inputs(1): MSIG1 (Ch1–2)

Tach inputs(1): MSIG2 (Ch 3–4)

E

F

Relay I/O(1): MSIG1 (I/O 1–2)

Relay I/O(1): MSIG2 (I/O 3–4)

G DIP switches for routing buffered sensor/tach inputs from the A6500-P-RTRM side of therack

H DIP switches for configuring sensor power On or Off(2)

(SW1, SW2, SW3, SW5, SW6, and SW7)

I Calibration test signal output port

(SMB connector)

A6500-M-RTRM (continued)Table D-1:

Termination panel

J -24 V sensor power input for eddy current sensors

(1) For Tach and Relay channels, leave the sensor power DIP switches in the OFF position.

(2) SW4 and SW8 correspond to tach and relay channels, and are not used.

A6500-M-BP backplane componentsTable D-2:

Backplane

K SysFail relay connector

L DC Power input connector for Prediction Side

M HUB network connector

N NIC network connector

O Chassis Ground lug

P Power On LED

Q +24 V Input LED

R Status LED

D.2 Internal wiring diagram for the CSI 2600

D.3 Terminal descriptorsEach channel has five terminals. The first two are for the plus (+) and minus (-) signalinputs. If the associated DIP switch is set to ON, these terminals will also supply +24 Vconstant current accelerometer power.

The second two are for the -24 V power supply for eddy current probes. These terminalsonly supply power if an external -24 V power supply is connected to the J19 power inputterminal at the edge of the termination panel.

NoteFor the CSI 2600, this connection is not used and the -24 V power is available on the panel-mountedPhoenix connector on the rear of the case.

The last terminal for each channel is a chassis ground for connecting the sensor cableshield.

Terminal descriptors for MSIG 1Table D-3:

J1 J2 J3 J4

CH1

SIG+1/+24V

CH5

SIG+5/+24V

CH9

SIG+9/+24V

TACH1

Tach+1

SIG-1/+24V return SIG-5/+24V return SIG-9/+24V return Tach-1

-24V -24V -24V -24V

Gnd (-24V return) Gnd (-24V return) Gnd (-24V return) Gnd (-24V return)

Chassis GND (Shield) Chassis GND (Shield) Chassis GND (Shield) Chassis GND (Shield)

CH2

SIG+2/+24V

CH6

SIG+6/+24V

CH10

SIG+10/+24V

TACH2

Tach+2


-24V -24V -24V -24V



CH3

SIG+3/+24V

CH7

SIG+7/+24V

CH11

SIG+11/+24V

I/O1

I/O+1

SIG-3/+24V return SIG-7/+24V return SIG-11/+24V return I/O-1

-24V -24V -24V -24V

Gnd (-24V return(1)) Gnd (-24V return(1)) Gnd (-24V return(1)) Gnd (-24V return(1))

Shield Shield Shield Shield

CH4

SIG+4/+24V

CH8

SIG+8/+24V

CH12

SIG+12/+24V

I/O2

I/O+2


-24V -24V -24V -24V



(1) -24 V terminals on I/O channels are not used for I/O connections.

Terminal descriptors for MSIG 2Table D-4:

J5 J6 J7 J8

CH13

SIG+13/+24V

CH17

SIG+17/+24V

CH21

SIG+21/+24V

TACH3

Tach+3


-24V -24V -24V -24V



CH14

SIG+14/+24V

CH18

SIG+18/+24V

CH22

SIG+22/+24V

TACH4

Tach+4


-24V -24V -24V -24V



CH15

SIG+15/+24V

CH19

SIG+19/+24V

CH23

SIG+23/+24V

I/O3

I/O+3


-24V -24V -24V -24V



CH16

SIG+16/+24V

CH20

SIG+20/+24V

CH24

SIG+24/+24V

I/O4

I/O+4


-24V -24V -24V -24V



D.4 Rear terminal power connections

Rear terminal power connectionsFigure D-2:

D.5 CSI 2600 DIP switch settingsEach signal input channel has an associated DIP switch for connecting accelerometerpower. For accelerometer channels that require power from the CSI 2600, set theassociated DIP switch to the right, or On position. For sensor channels that do not requirepower, set the associated DIP switch to the left or Off position.

NoteFor the Tach and Relay channels, the DIP switches must be left in the Off position.

Appendix ETroubleshooting

During the lifetime of a CSI 2600 system, an analyst may need to troubleshoot the following situations:TroubleshootingTable E-1:

Issue Solution/reference

FTP server IP address changed. Update boot flag settings.

Measurements in Online Watch orVibration Analysis seem incorrector inconsistent.

If two instruments are showing different measurements for the same signal, it islikely that:• Different units are being used by the two instruments.• The monitoring rack output signal is not an exact replica of the input signal,

rather it is a conditioned version.• The monitoring rack output signal is a current-level signal (4-20 mA) not a

voltage signal.

Online Watch/ OnlineConfiguration shows status ofNode(Unit)Down.

The following are possible solutions:1. Restart CsiO_Server service.2. Verify that IP addresses set in boot parameters match those set in AMS

Machinery Manager.3. With the unit connected to the network, ping the unit's IP address. If the ping

is successful, there is probably a configuration mismatch between the unit andthe server. Check the boot parameters. If the ping fails, there may be aphysical error (bad Ethernet connection, gateway between two units,mismatching IP addresses).

System Status LED is red. Establish a Telnet connection to check unit status. If there was a POST failure, aflag will be set, and the title of the failure will be listed. Use these details todiagnose the issue.

Automatic archive was not created. Predicate must change state from either FALSE or INDETERMINATE to TRUE.

Archive was truncated. An archive will have a status of Truncated if an analyst extracts a block of data acrossa gap in the time frame requested.

Unable to make changes to adatabase.

The system is in the process of storing an archive created with an earlier databaseconfiguration. Either wait for the archive to complete or cancel the archive.

The online server is attached to a different database. In RBM NetworkAdministration, change the database associated with the online server.

Troubleshooting

MHM-97453, Rev 1 101

Troubleshooting

102 MHM-97453, Rev 1

Index

Aaccelerometer supplies 34, 35

active displacement sensor 31

actuator 42–44

adaptive automatic triggering 31

Alarm Limit Set 16

Analysis Parameter Set 16

anti-aliasing filter 33

auto-archive 16, 64, 67

Axial Thrust predicate 20

BBNC connectors 3, 5, 6, 20, 28, 62, 93

Ccautions 7cleaning 6, 7

Collection Predicate 16

CPU Status LED 76

Ddamage 6, 7

DAT recorder mode 12, 13

Data Collection Set (DCS) 17

DHM 84, 85

Digital Multi Meter 84

DIP switch 97

Eepoxy mount, sensors 38

HHard Disk Drive (HDD) 12

Hard Drive Active LED 78

hazardous area 7Hub port 19

HyperTerminal 51

IInput Power LED 76

Internet Information Services (IIS) 45, 48

MMeasurement Point 17

MHM Remote 45

Modbus 3, 5, 6

Modbus Connect LED 77

Monitoring module 17

MtDbgMgr 45

NNAS hard drive 13

Network Server 45

NIC port 19

OObject Linking and Embedding for Process Control

(OPC) 3, 5, 6

on-board signal generator 83

Online Configuration 45

Online Server 45

Online Watch 45

Ppassive magnetic sensor 31

PeakVue 3, 5, 6

Phoenix connection 97

Power On Self Test (POST) 28, 76

precautions 6, 7

probe driver 44

PuTTY 51

QQuick-Connect base 39

RRadial Trip predicate 20

Root Mean Square (RMS) 23, 25, 26, 30

Ssensors

accelerometer supplies 34, 35

epoxy mount 38

milling process, stud mount 35

mounting tools 34, 35

Index

MHM-97453, Rev 1 103

pilot hole, stud mount 35

stud mount 35

Server Connect LED 77

signal inputsDC component 23

dynamic AC 23

process signals 23

tachometer 23

stud mount, sensors 35

swivel mount 39

SysFail relay 25, 93

System Status LED 77

Ttechnical support 2

Telnet 51

Transient Status LED 76

TTL pulse type sensor 31

VVibration Analysis 12, 13, 45

Wwarnings 7water 6, 7

Index

104 MHM-97453, Rev 1

Index

MHM-97453, Rev 1 105

MHM-97453

Rev 1

2014

Emerson Process ManagementMachinery Health Management835 Innovation DriveKnoxville, TN 37932 USAT +1 865-675-2400F +1 865-218-1401www.EmersonProcess.com

©2014, Emerson Process ManagementThe contents of this publication are presented for informationalpurposes only, and while every effort has been made to ensuretheir accuracy, they are not to be construed as warranties orguarantees, express or implied, regarding the products or servicesdescribed herein or their use or applicability. All sales are governedby our terms and conditions, which are available on request. Wereserve the right to modify or improve the designs or specificationsof our products at any time without notice.All rights reserved. The Emerson logo is a trademark and servicemark of Emerson Electric Co. All other marks are property of theirrespective owners.

User Guide MHM-97453, Rev 1 April 2014 CSI 2600 Machinery...

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